Service

Service
Workshop Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D3E80251958

CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat 2011 ...
4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 4
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . .a.ge. n.A.G.. .Vo. l.ks.w.a.ge. n. A. G. d. o. . . . . . . . . . . . . 51
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3 Engine cover panel . . . . . . . . . . . . . . . . . . . . b. y.V.o. . . . . . . . . . . . . . . . . . . . . . .o.t g.u.a . . . . . . . 59
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3.1 Removing and installing engine cover . .ho.ri.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . 59
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13 - Crankshaft group . . . . . . . . . . . . . . ....
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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1.5 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 spec

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1.6 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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15 - Cylinder head, valve gear sed.by. V. . . . . . . . . . . . . . . . . . . . g.ua.ra.n . . . . . . . . . . . . . . . . . 113
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1 Cylinder head . . . a.ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.o.r a. . . . . . . . . . . . . . . . . . 113
1.1 Assembly overviewss - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . 113
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1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.4 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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2.1 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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3.3 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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4.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.4 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.4 Removing and installing oil level and oil temperature sender . . . . . . . . . . . . . . . . . . . . . . 185
1.5 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.1 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 Removing and installing oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.3 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2.3 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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2.4 Removing and installing coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . .e.n .AG . .. V.o.lk.sw
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21 - Turbocharging/supercharging . . . . . . . .ut.ho. . . . . . .
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1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.4 Removing and installing charge pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
ss
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
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1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
form
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1.2 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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1.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

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2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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2.1 Assembly overview - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

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2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

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3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
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3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
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268
3.2 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
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3.3 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Prote AG.
3.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.5 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3.6 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.7 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.8 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
4.3 Removing and installing throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
5 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
6.1 Checking fuel pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
6.2 Removing and installing fuel pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6.3 Removing and installing fuel pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
6.4 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
6.5 Removing and installing differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.6 Removing and installing air mass meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Contents iii
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.1 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
9.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
9.2 Removing and installing engine control unit with protective housing . . . . . . . . . . . . . . . . . . 318
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V.o.lk.sw . a. . . . . . . . . . . . . 332
AG. gen A
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . .lk.s.wa. g.e.n. . . . . . . . . . . .G.d.oe. s.n.o . . . 332
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1.2 Aligning exhaust system free of stress . . . . . . . . . . e. d.b.y . . . . . . . . . . . . . . . . . . . . . . . . . g.ua. ra341
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1.3 Installation position of clamp . . . . . . . . . . . . . . . t.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
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2 Emission control . . . . . . . . . . . . . . . . . . . . . . s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 c
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2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
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2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
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3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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3.1 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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3.2 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
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3.3 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.4 Assembly overview - reducing agent delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3.5 Removing and installing reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
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3.6 Removing and installing injector for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
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3.7 Assembly overview - delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 369

3.8 Removing and installing heater element (heater cup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
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4 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

4.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 375
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4.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 376
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5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
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5.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
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5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 382
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5.3 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 384
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5.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
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5.5 Cleaning exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
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Prote AG.
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.1 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.2 Removing and installing automatic glow period control unit . . . . . . . . . . . . . . . . . . . . . . . . 397
1.3 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
1.4 Removing and installing engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
iv Contents
00 – Technical data
1 Identification
(VRL013148; Edition 06.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

⇒ “1.1.1 Engine number”, page 1
⇒ “1.1.2 Engine data”, page 1
1.1.1 Engine number

The first 3 characters of the four-character engine code refer to
the mechanical configuration of the engine. These are stamped
on the engine. The fourth digit shows the engine output and varies
according to engine control unit. The four-place engine code can
be found on the identification plate, the vehicle data sticker and
the engine control unit.
satelettronica
The engine number (“engine code” and “serial number”) can be
found at the joint between engine and gearbox -arrow-.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine codes can also be found on the vehicle data sticker.
The engine number consists of up to 9 charactersn(alphanumeric).AG. Volkswagen AG d
The first part (maximum 4 characters) makes olksw up the “engine
age oes
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code”, and the second part (6 characters), d by V the “serial number”. If gu
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1.1.2 Engine data

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Codes CFFA CFFB CFFD CFHB CFHC CFH CFGB CFG

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Manu‐
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Golf 11.09 ► 11.09 ► --- --- --- --- 11.09 ► ---
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Golf --- --- --- 11.09 ► 11.09 ► --- --- ---

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Ti‐ 05.10 ► 11.09 ► 05.10 ► --- --- --- 05.10 ► 11.1

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Tour‐ --- --- --- --- 08.10 ► 05.1 --- 0

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CC 10.10 ► 10.10 ► --- --- --- 12.1 --- 10.10 ►

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Pas‐ 10.10 ► 10.10 ► --- --- --- --- 10.10 ► 12.1

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Scir‐ --- --- --- 11.10 ► 11.10 ► --- 11.10 ► 02.1
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Exhaust These engines comply with the threshold values of the EU5 exhaust emissions standard
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1. Identification 1
Codes CFFA CFFB CFFD CFHB CFHC CFH CFGB CFG CFJA
F C
Dis‐ l 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
place‐
ment
Power kW 100/4200 103/4200 81/4200 100/4200 103/4200 81/4 125/4200 130/ 125/420
at 200 4200
rpm
Tor‐ Nm 320/ 320/ 280/ 350/ 350/ 280/ 350/ 380/ 350/
que at 1750 … 2500 1750 … 2500 1750 … 2750 1750 … 2500 1750 … 2500 1750 1750 … 2500 1750 1750 … 2
rpm … 27 to
50 2500
Bore ∅ 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0
mm
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5
Valves per 4 4 4 4 4 4 4 4 4
cylinder
Compres‐ 16.5 16.5 16.0 16.5 16.5 16.0 16.5 16.0 16.5
sion ratio
Fuel: acc. DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590 DIN DIN EN 590 DIN DIN EN 5
satelettronica
to EN EN
590 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4 1-3-4-2 1-3-4 1-3-4-2
-2 -2
Balancer Yes Yes Yes No No No Yes Yes No
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Catalytic Yes Yes d by Yes
Vo
Yes Yesgu
ara Yes Yes Yes Yes
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Exhaust gas Yes Yes s au Yes Yes Yes r aYes
c Yes Yes Yes
recirculation s
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Charging Yes Yes Yes Yes Yes Yespt Yes Yes Yes
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Charge air Yes Yes Yes Yes Yes Yes Yes Yes Yes
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Particulate Yes Yes Yes Yes Yes Yes Yes Yes Yes
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1) only for India, South America and Russia

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2) Particulate reduction system instead of particulate filter

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2 Rep. gr.00 - Technical data

2 Safety information
⇒ “2.1 Safety measures when working on fuel supply”,
page 3
⇒ “2.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
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⇒ “2.3 Safety measures when working on vehiclesowith
lksw a start/
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stop system”, page 4 db
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⇒ “2.4 Safety precautions when working on tho the cooling system”, or
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page 4 ss ac
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⇒ “2.5 Safety precautions when working on the SCR system”,
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⇒ “2.6 Safety precautions when working on exhaust system”,
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page 5
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2.1 Safety measures when working on fuel
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WARNING
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The fuel line is under pressure.
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Fuel poses danger of injury to eyes and skin.
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Wear protective goggles and protective clothing to avoid injury

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and contact with the skin. Wrap a cloth around the connection
at
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before loosening hose connections. Then reduce pressure by
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carefully opening the connection.
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To prevent injuries to persons and destruction of the injection and

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glow plug system, the following must be noted:
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♦ Always switch off the ignition before connecting or discon‐ rig ht
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necting electrical wiring of injection and glow plug system or
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connecting/disconnecting tester cables. Prote AG.
♦ Wash the engine only with the ignition switched off.

♦ Entries have been stored in the event memory of the engine
control unit if the engine was started after electrical connectors
had been disconnected: Read event memory in vehicle
self-diagnosis ⇒ Vehicle diagnostic tester .
Caution
♦ Observe measures for disconnecting battery ⇒ Electrical

system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
2. Safety information 3
2.2 Safety precautions when using testers

and measuring instruments during a
road test
AG. Volkswagen AG d
Note the following if testers and measuring instruments lhave
wageto
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be used during a road test: db
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♦ Test instruments and measuring equipment uthmust always be
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secured to the rear seat and operated by asssecond
a person from c
this location.
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♦ Operating from the front passenger seat may result in an ac‐
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cident caused by releasing the front passenger air bag which
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can cause injuries to the person sitting there.
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2.3 Safety measures when working on ve‐
h re
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spec
hicles with a start/stop system
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WARNING
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Risk of injury due to automatic start of engine on vehicles with
a start/stop system.
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♦ In vehicles with an activated start/stop system (indicated
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by a message in the dash panel insert), the engine may
form
mer
start automatically.
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♦ You must therefore ensure that the Start/Stop system is

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deactivated when working on vehicle (switch ignition off,
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switch ignition on again as required).
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2.4 Safety precautions when working on the Cop py
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WARNING
The cooling system is under pressure when the engine is hot!

Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
Caution
Danger of overheating due to incorrectly fitted cap.

♦ Tighten cap of coolant expansion tank until it engages.

2.5 Safety precautions when working on the

SCR system
WARNING
♦ The reducing agent can irritate skin, eyes and respiratory

organs.
♦ In the event of skin contact with this fluid, immediately
wash off with plenty of water.
♦ Seek medical attention if necessary.
Caution
Protect separated electrical connections against wetting from

reducing agent by suitable means, e.g. plastic bag and cable
ties. Due to the high tendency to creep combined with subse‐
quent crystallisation of the reducing agent, the electrical con‐
nections can be damaged.
satelettronica
Caution
Seal all openings of the hose and connections immediately

with suitable sealing plugs in order to prevent the ingress of
dirt. Even very small particles of dirt can cause considerable
damage to the system. lkswage es n
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Make sure that no reducing agent gets onto the trim panels or
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parts of vehicle body.
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If this occurs, wash out reducing agent using clear water and
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a lint-free cotton cloth. h re

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If the reducing agent has already crystallised, use warm water
es, in part or in w
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and a sponge.
Reducing agent that has not been removed will crystallise and
damage the surface after some time.
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Information concerning storage and disposal ⇒ ServiceNet →

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Environmental protection → Workshop disposal ! Request

country specific information from importer concerning storage
nf
and disposal.
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2.6 Safety precautions when working on exhaust system

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Risk of poisoning due to chemical substances

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Exhaust gas temperature senders may contain chemical sub‐

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stances. There is a risk of poisoning or injuries to respiratory Cop py
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– Never open an exhaust gas temperature sender by cutting,
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Prote AG.
2. Safety information 5
Risk of injury due to hot condensate and particles in the exhaust

system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation. n AG. Volkswagen A age G do
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Risk of damage to flexible joint.
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♦ Do not allow the flexible joint to kink by more than 10°.
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♦ Install flexible joint so that it is not under tension.
es, in part or in w
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♦ Do not damage wire mesh on decoupling element.
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3 Repair notes
⇒ “3.1 Rules for cleanliness”, page 7
⇒ “3.2 Foreign objects in engine”, page 8
⇒ “3.3 Checking vacuum system”, page 8
3.1 Rules for cleanliness
3.1.1 When working on fuel supply/injection

system
When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
satelettronica
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that wagen AG. Volkswagen AG doe
have been kept unpackaged (for example in toolboxes). y Volks s no
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♦ When the system is open: Do not work with compressedris air. nte
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The vehicle should not be moved. sa
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♦ Also ensure that no diesel fuel comes into contact with the
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coolant hoses. Should this occur, the hoses must be cleaned
an
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immediately. Damaged hoses must be renewed.
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3.1.2 When working on turbocharger
wit
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spec
Caution
es, in part or in w
t to the co
If a mechanical fault is found on the turbocharger, e.g. a de‐
stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
rrectness of i
must be carried out:
l purpos
♦ Check air filter housing, air filter element and intake hoses
for dirt/soiling.
nf
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♦ Check the whole charge air path and charge air cooler for
rm
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foreign objects. If foreign objects are found in the charge

om
air system, the charged air routing must be cleaned and

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the charge air cooler must be renewed, if necessary.

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♦ If bearing damage is evident on the removed turbocharg‐

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er, change the engine oil and filter.

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When working on the turbocharger, pay careful attention to the
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following rules for cleanliness: Prote AG.
♦ Thoroughly clean all unions and adjacent areas before dis‐

connecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
3. Repair notes 7
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ Transportation and protective packaging and sealing caps
must be removed only immediately before fitting.
♦ When making repairs, remove oil from connection and hose
ends.
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
3.2 Foreign objects in engine
Note
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If large quantities of swarf oredmetal particles (caused, for example,
by ua
ra
by partial seizure of thethcrankshaft
or
is or conrod bearings) are found ntee
in the engine oil whens auperforming repairs, clean the oil passages or
ac
thoroughly and renew the engine oil cooler in order to prevent
s
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subsequent damage.
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3.3 Checking vacuum system
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All information on the vacuum system ⇒ page 264
h re
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spec
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10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Separating engine and gearbox”, page 28
⇒ “1.3 Securing engine on engine and gearbox support”,
page 33
⇒ “1.4 Installing engine”, page 34
1.1 Removing engine

⇒ “1.1.1 Removing engine, Golf, Golf Plus, Touran, Scirocco and
Tiguan”, page 9
⇒ “1.1.2 Removing engine, Passat, Eos and CC”, page 16
1.1.1 Removing engine, Golf, Golf Plus, Tour‐

an, Scirocco and Tiguan
satelettronica
Special tools and workshop equipment required
♦ Workshop hoist - VAS 6100-
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♦ Lifting tackle - 3033-
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♦ Read out radio anti-theft code as the battery earth strap has
to be disconnected during the next work steps.
♦ The engine is removed forwards together with the gearbox.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
1. Removing and installing engine 9

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WARNING ir se
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When performing any repair work, especially
ss in the engine
compartment, pay attention to the following due to the cramped
ce
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un
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conditions:
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♦ Route lines of any kind so that the original routing can be
pe
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restored.
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♦ Ensure that there is sufficient clearance to all moving or hole
hot components.
spec
es, in part or in w
t to the co
– With ignition switched off, disconnect battery earth strap. ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
rrectness of i
connecting battery
l purpos
– Remove engine cover panel ⇒ page 9 .

– Remove air filter housing with air mass meter and connecting
nform
ercia
pipe ⇒ page 293 .

m
a
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
com
tion in
Removing and installing battery .
r
satelettronica
te o
thi
s
– Unscrew bolts -arrows- and remove battery tray.
iva
do
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cum
– Remove fuel filter and supplementary fuel pump - V393- or fuel
fo
en
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pump 2 - V277- ⇒ Rep. gr. 20 ; Fuel filter; Removing and

t.
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op
installing fuel filter .
C py
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– Remove noise insulation ⇒ General body repairs, exterior; cop Vo
by lksw
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Prote AG.
sulation .
– Drain coolant ⇒ page 209 .
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐
ing the refrigerant circuit .
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Removing and installing lock carrier .
– Unscrew bolt -arrow-, and place filler neck for windscreen

washer system reservoir to one side.
– Remove coolant expansion tank and place on engine.
10 Rep. gr.10 - Removing and installing engine

– Unscrew captive bolt -arrow-, twist intake hose -A- clockwise

out of its retainer and remove it.
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– Pull off vacuum hoses -1- and -2- for charge air control.
ole,
spec
t to the co
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– Separate connectors for exhaust gas temperature sender 1 -

iv
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G235- -1-, for lambda probe - G39- -3- and for exhaust gas
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temperature sender 4 - G648- -2-.
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– Disconnect connector for exhaust gas temperature sender 3 -

G495- -1- (secured behind bracket).
– Release lines from retainers on plenum chamber bulkhead
and on turbocharger.
– Pull vacuum line off vacuum pump.
Caution
Danger of damage to air conditioner compressor, refrigerant

lines and hoses.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Unscrew securing bolt for refrigerant line -arrow- on air con‐

ditioner compressor.
– Pull off refrigerant line on air conditioner compressor and place
to one side without kinking. wage
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– Disconnect quick-release couplings for heat exchanger
spec
-arrows- on plenum chamber bulkhead.
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
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– Unscrew positive cable -arrow- from starter at central electrics
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and place on engine.
fo
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Vehicles with dual clutch gearbox
Co
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– Remove gear-change mechanism from gearbox ⇒ Rep. gr. yri
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34 ; Gear-change mechanism; Assembly overview - Gear-
c by lksw
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change mechanism .
Prote AG.

– To release, turn catch of mechatronic connector -arrow- and

pull connector off.
Vehicles with manual gearbox
– Remove gear-change mechanism from gearbox ⇒ Rep. gr.
change mechanism .
– Remove pipe-hose line or plastic line from clutch slave cylin‐
der ⇒ Rep. gr. 30 ; Clutch control mechanism; Removing and
installing lines for clutch control mechanism .
Continued for all vehicles
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.
gr. 92 ; Windscreen wiper system; Removing and installing
windscreen wiper arms .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulk‐
head .
Touran
– Remove wiper frame with rod and wiper motor ⇒ Electrical
satelettronica
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper motor .
– Remove engine control unit from its bracket ⇒ page 311 .
– Release connector for engine wiring harness -arrow- and pull

it off engine control unit.
AG. Volkswagen AG d
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– Detach connectors -1- and-2- from left longitudinal member of

es, in part or in w
t to the co
vehicle.
– Unbolt earth cable on gearbox.
rrectness of i
– Open locking mechanism -A- of opening in plenum chamber

bulkhead.
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Prote AG.

CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus agen2009 ➤ , Passat
AG. Volkswagen AG d2011 ...
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– Pull out upper part upwards and remove engine
au
th wiring harness e or
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from cable guide. ss
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pt
– Disconnect all connectors between starter, gearbox and body.
du
an
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew securing bolt -arrow- on upper bracket of particulate

filter and loosen securing bolt of bracket on cylinder head one
turn.
nf
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– Detach connector from oil level and oil temperature sender -
m
m
atio
G266- .
om
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– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
thi
te
gr. 40 ; Drive shaft; Removing and installing drive shaft .
sd
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Cop py
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Prote AG.
– Unscrew bolts -1…3- and remove pendulum support.
Vehicles with all-wheel drive
– Mark position of flexible coupling and bevel box flange relative

to each other for reinstallation.
– Unbolt propshaft from bevel box -arrows-. To do this, coun‐
terhold on triangular flange using a lever.

– Push engine/gearbox assembly slightly towards front (in di‐

rection of front end) and pull propshaft off bevel box.
Caution
Risk of damage to seal -arrow- in propshaft flange.

♦ Push propshaft horizontally as far back as possible and
towards left vehicle side.
Note
If seal is damaged, propshaft must be renewed.
Vehicles with auxiliary heater
– Clamp off coolant hoses -1- and -2- with hose clips up to Ø
25 mm - 3094- and pull coolant hoses from additional heater.
satelettronica
– Remove securing clamp -1- between particulate filter and tur‐
bocharger.
– Unscrew securing nuts above particulate filter bracket with
ratchet ring spanner - T10384- e.n AG. Volkswagen AG
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– Unscrew securing nuts -arrows- of particulate filter bracket

hole
spec
-A- on crankcase and remove bracket.

es, in part or in w
t to the co
– Push particulate filter aside and secure on plenum chamber

bulkhead by suitable means.
rrectness of i
Note
l purpos
Check that all hose and line connections between engine, gear‐
nf
box and body have been detached.

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15
by c lksw
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1. Removing and installing engine
agen
Prote AG.
– Attach lifting tackle - 3033- as follows and take up weight of

»engine/gearbox assembly« in installation position using
workshop crane - VAS 6100- .
Vibration damper end:
• Item 2.
Flywheel end:
• Item 8.
– Remove securing bolts -arrows- of assembly mounting on en‐

gine.
AG. Volkswagen AG d
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– Remove securing bolts -arrows- of assembly mounting on
itte
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gearbox.
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Note
hole
spec
es, in part or in w
Carefully guide »engine/gearbox assembly« when removing to
t to the co
avoid damage to body.
rrectness of i
– Lower »engine/gearbox assembly« slightly and remove for‐
wards.
l purpos
Secure engine to engine and gearbox support - VAS 6095- to

carry out repairs ⇒ page 33 .
nf
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1.1.2 Removing engine, Passat, Eos and CC

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Note
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♦ Read out radio anti-theft code as the battery earth strap has
t.
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to be disconnected during the next work steps. C py
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♦ The engine is removed downwards together with the gearbox. copy Vo
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♦ All cable ties that are opened or cut through when the engine
AG.
is removed must be renewed/replaced in the same position

when the engine is installed.

Special tools and workshop

equipment required
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♦ Hose clamps to 25 mm - 3094-

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♦ Engine support - T10012-

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♦ Torque wrench - V.A.G 1331-

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♦ Engine and gearbox jack - V.A.G 1383 A-

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♦ Stepladder - VAS 5085- Cop py
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♦ Hose clamp pliers - VAS 6340-
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♦ Drip tray for workshop hoist - VAS 6208-
Removing
AG. Volkswagen A gen G do
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– Disconnect earth strap by
Vat
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Electrical system;riRep.
se
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connecting battery
ut
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– Disconnect electrical
s
connector on air mass meter - G70- .
ce
le
satelettronica
un
pt
an
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pipe ⇒ page 293 .
rm
ab
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ility
– Unscrew bolts -arrows- and remove air duct from lock carrier.
ot
wit
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– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery; h re

hole
spec
es, in part or in w
t to the co

Vehicles with air conditioner:
rrectness of i
– Extract refrigerant from air conditioning system ⇒ Heating, air

conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐
l purpos
ing the refrigerant circuit .

nform
ercia
Caution
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tio
Danger of damage to air conditioner compressor, refrigerant

n in
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lines and hoses.

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Cop py
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– Unscrew refrigerant lines -arrows- from air conditioner com‐
ht
pyri by
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pressor.
c by lksw
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Prote AG.
Continued for all vehicles:
– Remove engine control unit - J623- from its bracket
⇒ page 311 .

– Pull engine wiring harness connector -arrow- off engine con‐

trol unit.
– Release feed-through for engine wiring harness -arrow- and

pull off upwards.
satelettronica
– Unscrew bolts -arrows- and remove battery mounting bracket
-1-.
– Disconnect connectors.
AG. Volkswagen AG d
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♦ -1- Exhaust gas temperature sender 1 - G235-

itte
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ab

ility
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♦ -3- lambda probe - G39-

h re
hole
spec
♦ -4- Charge pressure control solenoid valve - N75-

es, in part or in w
t to the co
– Unscrew the bolts -arrows- and place charge pressure control

solenoid valve - N75- with vacuum lines on the engine.
– Guide lines out of brackets on plenum chamber bulkhead and
rrectness of i
on turbocharger.
l purpos
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19
AG.
1. Removing and installing engine
– Disconnect quick-release couplings for heat exchanger

-arrows- on plenum chamber bulkhead.
– Remove coolant expansion tank and place on engine.
– Loosen (captive) bolt -arrow-. Twist intake hose -A- clockwise

out of its bracket and remove it.
satelettronica
G. Volkswagen AG d
– Pull off vacuum hoses -1- and -2- for charge air control.
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spec
es, in part or in w
t to the co
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
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Cop py
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Prote AG.

– Remove lines on the central electrical system -arrows- and

place on the engine.
– Open cable guide retainer -arrows-.
satelettronica
AG. Volkswagen AG d
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– Disconnect engine
utho wiring harness connector -arrow- below lefte or
headlight. ss a ac
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nl
pt
du
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itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Free connector -1- and disconnect.

l purpos
– Open retainer -2- for wiring guide located below.

nf
ercia
– Remove wiring harness for engine control unit from wiring duct
orm
and place on engine.

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Cop py
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Prote AG.

– Pull vacuum hose -arrow- off brake servo.

Vehicles with dual clutch gearbox
change mechanism .
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– To release, turn catch of mechatronic connector -arrow-
ss aand c
pull connector off.
ce
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un
pt
an
d
Vehicles with manual gearbox
itte
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rm
ab
pe
ility
ot
wit
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change mechanism .
h re
hole
spec
– Remove pipe-hose line or plastic line from clutch slave cylin‐
satelettronica
es, in part or in w
der ⇒ Rep. gr. 30 ; Clutch control mechanism; Removing and
t to the co
installing lines for clutch control mechanism .
rrectness of i
– Disconnect all connectors between starter, gearbox and body.
l purpos
WARNING
nform
ercia
Danger of scalding from very hot fuel.

m
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com
tion in
♦ In extreme cases, the temperature of the fuel and the fuel
r
te o
thi
lines can reach 100 °C after the engine is switched off.
s
iva
Allow the fuel to cool down before disconnecting the lines
do
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rp
c
- risk of scalding.
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♦ Wear protective gloves.
Co
Cop py
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♦ Wear protective goggles.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open plug-in connectors -A- and -B- of fuel lines and pull fuel
lines off.

– Unclip bracket for coolant hose -1-.

– Remove fuel filter securing bolts and place fuel filter on engine.
– Unplug connector at pressure differential sender - G505- -2-,

unscrew securing bolt -1-.
satelettronica
AG. Volkswagen AG d
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– Unclip linesafor
ut pressure differential sender - G505- out of up‐ ra
c
per toothed belt guard together with bracket -1-. ss
ce
le
un
pt
– Lay pressure differential sender - G505- on particulate filter

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– Unscrew bolt -1-.

– Removing radiator ⇒ page 239 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove lower wheel housing liners on left and right ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing wheel housing liner .
– Remove left charge air line by loosening hose clips -1- and
-2-.
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-2-.
– Seal open lines and unions with clean plugs from engine seal‐
ing plug set - VAS 6122- .
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– Unscrew bolts -1 … 3- and remove pendulum support.

Vehicles with auxiliary heater
– Clamp off coolant hoses -1- and -2- with hose clips up to Ø
25 mm - 3094- and pull coolant hoses from additional heater.
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– Tie up particulate filter to rear.
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Caution
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Risk of damage to flexible joint
s
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– Unscrew bolts -1- and remove heat shield for right drive shaft.
– Unbolt left and right drive shafts from flange shafts on gearbox.

– Mark position of flexible coupling and bevel box flange relative

to each other for reinstallation.
– Unbolt propshaft from bevel box -arrows-. To do this, coun‐
terhold on triangular flange using a lever.
– Push engine/gearbox assembly slightly towards front (in di‐

rection of front end) and pull propshaft off bevel box.
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– Tie up propshaft on left vehicle side.
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– Unscrew nuts (qty. 3) of swivel joint on right suspension link
⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower sus‐
l purpos
pension link, swivel joint; Assembly overview - lower suspen‐

sion link, swivel joint .
nform
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– Separate swivel joint from right transverse link ⇒ Running

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gear, axles, steering; Rep. gr. 40 ; Lower suspension link,
om
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swivel joint; Assembly overview – lower suspension link, swiv‐

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– Disconnect electrical connector -arrow- on oil level and oil

for
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temperature sender - G266- .

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– Release hose clip -2-.

– Unscrew bolts -arrows-.
– Separate electrical connection -1- on charge pressure sender
- G31- / intake air temperature sensor - G42- and remove air
pipe.
– Free off coolant hose -3-.
– Unscrew securing bolt -arrow- for continued coolant circulation
satelettronica
pump.
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CC 2010 ➤ , Eos rise 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009
d b ara ➤ , Passat 2011
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4-cylinder common
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ra
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– Bolt engine bracket - T10012- with securing bolt -1- and nut
nl
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-2- to cylinder block (specified torque: approx. 20 Nm).
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– Insert engine bracket - T10012- in engine and gearbox jack -
ility
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V.A.G 1383 A- .
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VAS 5085- .
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– Unscrew bolts -arrows- for engine mounting.
– Unscrew bolts -arrows- for gearbox mounting.
Caution
Danger of damage to hose and line connections as well as

engine compartment.
♦ Check that all hose and line connections between engine,
gearbox, subframe and body have been disconnected.
♦ When lowering, carefully guide engine/gearbox assembly
out of engine compartment.
♦ Ensure clearance to air conditioner compressor.
– First lower engine/gearbox assembly slightly.

– Then swing gearbox end of engine/gearbox assembly for‐
wards and only then lower further.
1.2 Separating engine and gearbox

⇒ “1.2.1 Separating engine from gearbox”, page 28
⇒ “1.2.2 Separating engine from dual clutch gearbox”,
page 31
1.2.1 Separating engine from gearbox


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♦ Lifting tackle - T40013-
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Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Unscrew bolts -arrows- and remove gearbox support.

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– Unscrew bolts -1- and -2- and remove starter from gearbox.
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Vehicles with all-wheel drive:
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– Unscrew bolts -arrows 2, 3- for bevel box bracket.
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– Attach lifting tackle - T40013- to gearbox and close lock.
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /
2- to lifting tackle.
– Unscrew bolts -1, 2, 5, 6, 7, 8- from gearbox to engine con‐

nection.
– Pull gearbox off engine.

1.2.2 Separating engine from dual clutch

gearbox
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♦ Adapter - 10 - 222 A /20- ir se
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Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Remove coolant hoses from gear oil cooler, loosen hose clips
-arrows- for this.

– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and

secure with pin -arrow-.
– Attach workshop hoist - VAS 6100- to lifting tackle using hook
- 10 - 222 A /20- .
– Free wiring harnesses -arrows- and electrical connector -1- at
satelettronica
bracket.
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– Unscrew bolts -1- and -2- and remove starter from gearbox.
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– Unscrew remaining bolts -1, 3, 5, 6, 7, 8, 9, 10- from gearbox

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– Pull gearbox off engine.
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1.3 Securing engine on engine and gearbox

support
Before carrying out repair work, secure engine in engine and
gearbox support - VAS 6095/1- using universal mounting - VAS
6095- .
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♦ Lifting tackle - 3033-

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine and gearbox support - VAS 6095-
Procedure
– Unbolt gearbox.
– If vehicle has an automatic gearbox, secure torque converter
against “falling out” after separating engine from gearbox.

– Attach lifting tackle - 3033- as follows and lift from engine and
gearbox jack - VAS 6100- using workshop crane - V.A.G 1383
A- .
Flywheel end: position 4.
Vibration damper end: position 8.
– Secure engine on engine and gearbox support - VAS 6095/1-
using universal mounting - VAS 6095- .
1.4 Installing engine

⇒ “1.4.1 Notes on installing”, page 34
1.4.1 Notes on installing
Caution
satelettronica
When installing a new short engine, it is compulsory to fix and
tighten the clamping jaws of the injectors with the specified
torque after installing the high-pressure lines ⇒ page 268 .
Clamping jaws are only secured »hand-tight« for setting the
injectors while installing high-pressure lines. Non-observance
of these notes may lead to damage to engine.
Install in reverse order of removal. During this procedure, observe

the following:
Repairing the clutch:
♦ Vehicles with manual gearbox ⇒ Rep. gr. 38 ; Clutch; Dis‐
mantling and reassembling clutch . . Volkswag
AG en AG
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♦ Vehicles with dual clutch yV
gearbox
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⇒ Rep. gr. 38 ; Clutch;
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Dismantling and reassembling
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– Check whethers adowel
ut sleeves for centring engine/gearbox or
ac
have been fitted in cylinder block, insert if necessary.
s
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Fastening, manual gearbox to engine

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Item Bolt Nm
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21) M12x165 80
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3 M10×105 40
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4 M10x50 40
52) M12x65 80
rrectness of i
A Dowel sleeves for centring

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• 1) Bolt with M8 stud.

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• 2) Bolted into gearbox from engine side.

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Rep. gr.10 - Removing and installing engine
Fastening, dual clutch gearbox to engine

Item Bolt Nm
1, 3, 10 M12x55 80
5 M12x65 80
6, 7, 8 M10x50 40
9 M12x70
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Starter attachment ⇒ Electrical
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sedb Rep. gr. 27 ; Starter; Removing
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– When installing the engine and gearbox assembly, make sure
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♦ Specified torques for engine/gearbox assembly mountings
satelettronica
⇒ page 37
rrectne
♦ Electrical connections and routing of wiring ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Starter; Removing and installing starter .
ss o
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Vehicles with manual gearbox:
inform
mer
– Install hydraulic line for the hydraulic clutch ⇒ Rep. gr. 30 ;

atio
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Clutch control mechanism; Removing and installing lines for

o
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clutch control mechanism .

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– Install gearbox selector mechanism and adjust if necessary ⇒

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Rep. gr. 34 ; Selector mechanism; Assembly overview - se‐

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lector mechanism .
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– Install lay selector lever and adjust if necessary ⇒ Rep. gr.
cop Vo
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34 ; Manual gearbox; Removing and installing lay selector lev‐
agen
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er .
Note
♦ After working on particulate filter, ensure it is installed free of

stress.
♦ Renew self-locking nuts, seals, gaskets and securing clamps.
Caution
Avoid damage of flexible joint behind particulate filter. When

removing and installing:
♦ Do not allow the flexible joint to kink by more than 10°.
Secure with transportation lock - T10404- .
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
– Install particulate filter ⇒ page 347 .

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– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;
itte
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Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
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– Install heat shield for drive shaft (right-side), if there is one
h re
-arrows-.
hole
spec
es, in part or in w
Vehicles with manual gearbox:
t to the co
Specified torque ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Specified torques for gearbox .
rrectness of i
l purpos
Specified torque ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Specified torques for gearbox .
nform
ercia
m
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– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 ;
ion
c
Propshaft; Removing and installing propshaft .
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– Secure refrigerant lines to air conditioner compressor and

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condenser such that they are stress-free ⇒ Heater, air condi‐
Co
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tioning system; Rep. gr. 87 ; Refrigerant circuit; Detaching/
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– Charge air conditioning system ⇒ Heating, air conditioning
agen
Prote AG.
system; Rep. gr. 00 ; Repair instructions; Exhausting refrig‐
erant circuit .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Observe notes after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Add coolant ⇒ page 209 .
– Filling fuel system ⇒ page 262 .
– Read event memories of all control units. Clear all entries from
event memory which may have occurred during installation
⇒ Vehicle diagnostic tester “Vehicle self-diagnosis”.
Specified torques
Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm1)
1) Specified torque for M12 collar bolts: 75 Nm

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 37
⇒ “2.2 Supporting engine in installation position”, page 38
⇒ “2.3 Adjusting assembly mountings”, page 51
2.1 Assembly overview - assembly mount‐

ings
⇒ “2.1.1 Assembly overview - assembly mounting for Golf,
Golf Plus, Touran, Passat, Eos, Scirocco and CC”, page 37
⇒ “2.1.2 Assembly overview – assembly mountings, Tiguan”,
page 38
2.1.1 Assembly overview - assembly mount‐

ing for Golf, Golf Plus, Touran, Passat,
Eos, Scirocco and CC
Engine mounting
satelettronica
A 1) = 40 Nm + turn 90° further
B 1) = 60 Nm + 90° further
C 1) = 20 Nm + 90° further
1) Renew
Gearbox mounting
1 1) = 40 Nm + 90° further
2 1) = 60 Nm + 90° further agen
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B 1) = 50 Nm + 90° further
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C 1) = 100 Nm + 90° further

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2. Assembly mountings 37
2.1.2 Assembly overview – assembly mount‐

ings, Tiguan
Engine mounting
B 1) = 60 Nm + 90° further
C 1) = 20 Nm + 90° further
1) Renew AG. Volkswagen AG d
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Gearbox mounting
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1 1) = 40 Nm + 90° further
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2 1) = 60 Nm + 90° further
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Pendulum support
A (M10 x 35)1) = 50 Nm + 90° further
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A (M12 x 1.5 x 50)1) = 60 Nm + 90° further

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B (M10 x 75)1) = 50 Nm + 90° further

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B (M12 x 1.5 x 85)1) = 60 Nm + 90° further

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C 1) = 100 Nm + 90° further

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2.2 Supporting engine in installation posi‐

tion
⇒ “2.2.1 Supporting engine in installation position, Golf and Scir‐
occo”, page 38
⇒ “2.2.2 Supporting engine in installation position, Tiguan”, page
41
⇒ “2.2.3 Supporting engine in installation position, Golf Plus”,
page 43
⇒ “2.2.4 Supporting engine in installation position, Touran”, page
45
⇒ “2.2.5 Supporting engine in installation position, Passat, Eos
and CC”, page 48
2.2.1 Supporting engine in installation posi‐

tion, Golf and Scirocco

♦ Support - 10-222 A-
♦ Adapter - 10-222 A/3-
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♦ Adapter - 10-222 A/1-

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restored.
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– Remove air filter housing ⇒ page 293 .
– Remove intake hose between air mass meter - G70- and in‐
take connecting pipe.
Caution
satelettronica
Risk of irreparable damage to electronic components when
disconnecting battery .
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– Disconnect earth wire -arrow- from battery with ignition switch‐

ed off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnect‐
ing and connecting battery .
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mountings if the engine is supported on the support bracket -
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deformations.

Note

10-222 A- .
2.3 Adjusting assembly mountings
satelettronica
⇒ “2.3.1 Adjusting assembly mounting, Golf and Scirocco”, page
51
⇒ “2.3.2 Adjusting assembly mountings, Tiguan”, page 53
⇒ “2.3.3 Adjusting assembly mounting, Golf Plus”, page 54
⇒ “2.3.4 Adjusting assembly mountings, Touran”, page 56
⇒ “2.3.5 Adjusting assembly mounting, Passat, Eos and CC”,
page 57
2.3.1 Adjusting assembly mounting, Golf and

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– Renew engine mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
– Renew gearbox mounting bolts -arrows- in succession (if not

– Loosen bolts for support arms on engine side and on gearbox
side by about two turns each.
satelettronica
Engine mounting
• There must be a distance -a- of at least 10 mm between engine
bracket and longitudinal member (right side).
• The side surface of the engine bracket -2- should be located
parallel to the support arm -1-.
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quence of removal. During this procedure, observe the following:
l purpos
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3 Engine cover panel

⇒ “3.1 Removing and installing engine cover”, page 59
3.1 Removing and installing engine cover

Removing
Caution
The engine cover retainer on the cylinder head cover can break
if not removed correctly. Always remove the engine cover pan‐
el according to the following instructions.
– Pull engine cover panel upwards out of fastening elements in

areas of -arrows- and in sequence shown. To do this, reach
as far as possible under engine cover.
Installing
Caution
satelettronica
Before installing engine cover panel, check the 4 securing el‐
ements (ball sockets) in the correct positions. Reset to correct
position if necessary. Otherwise the engine cover panel will be
damaged.
– If necessary, press engine cover panel ball sockets into cor‐

rect position.
– Position engine cover panel on securing points and press cor‐
ners into fasteners.
AG. Volkswagen AG d
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rrectness of i
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page 69
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element and air conditioner compressor”, page 60
⇒ “1.1.2 Assembly overview - poly V-belt drive with tensioning
roller and air conditioner compressor”, page 62
⇒ “1.1.3 Assembly overview - poly V-belt drive”, page 64
1.1.1 Assembly overview - poly V-belt drive with tensioning element and air con‐
ditioner compressor
60 Rep. gr.13 - Crankshaft group

1 - Belt pulley and vibration

damper
❑ Offset holes make as‐
sembly possible in one
position only
2 - 25 Nm
3 - Alternator
4 - Bracket
❑ For ancillaries
❑ Removing and installing
⇒ page 69
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❑ Mark direction of rota‐
hole
spec
tion before removing
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❑ Check for wear
❑ Do not kink
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⇒ page 64
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1. Cylinder block (pulley end) 61

1.1.2 Assembly overview - poly V-belt drive with tensioning roller and air condi‐
tioner compressor
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
⇒ page 66
❑ Do not kink
❑ When installing, make
sure it is properly seated
on poly V-belt pulleys.
2 - Tensioning roller for poly V-
belt
⇒ page 66
satelettronica
❑ Coat guide surfaces
with lubricating paste;
lubricating paste ⇒
Electronic Parts Cata‐
logue .
3 - Vibration damper
❑ With poly V-belt pulley
position only
❑ Installation position:
hole in vibration damper agen AG. Volkswagen AG do
must align over protru‐ olks
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⇒ Electronic parts catalogue

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5 - Dowel sleeve
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hole
❑ Check for correct seating in ancillary bracket.

spec
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6 - 20 Nm + 90°
t to the co
7 - 50 Nm + 90°
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8 - Idler roller
❑ For toothed belt
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9 - 15 Nm
nform
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10 - Idler roller
m
❑ For toothed belt

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11 - Ancillary bracket
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❑ Removing and installing ⇒ page 69

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12 - High-pressure pump
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13 - Bolt
❑ Specified torque and tightening sequence ⇒ page 70
14 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator;
gen AG
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16 - Air conditioner compressor tho eo
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❑ Removing and installing ⇒ Heating, airssconditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
c
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and installing air conditioner compressor
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17 - 25 Nm
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18 - Dowel sleeve ot p
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❑ Check for correct seating in ancillary bracket.
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spec
19 - Bolt
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Tensioning roller for poly V-belt - specified torque and tightening
sequence
satelettronica
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♦ Renew bolt for tensioning roller.

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♦ Coat guide surfaces of tensioning roller with solid lubricating
thi
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paste with a brush; solid lubricating paste ⇒ Parts Catalogue .

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1) -Arrow- Screw in by hand as far as stop Prote
cted AG.
agen
• the poly V-belt is tensioned
2) -Arrow- turn until tensioning roller bolt reaches

stop
• the poly V-belt is tensioned further
3) -Arrow- Turn back 90°

4) -Arrow- 30 Nm
5) -Arrow- Turn 90° further

1.1.3 Assembly overview - poly V-belt drive
1 - Vibration damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft pul‐
ley.
2 - 25 Nm
3 - Alternator
5 - Poly V-belt
❑ Renew
⇒ page 67
satelettronica
AG. Volkswagen AG d
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1.2 Removing and installing poly-V belt

spec
es, in part or in w
t to the co
⇒ “1.2.1 Removing and installing poly V-belt with tensioning ele‐

ment and air conditioner compressor”, page 64
rrectness of i
⇒ “1.2.2 Removing and installing poly V-belt with tensioning roller

and air conditioner compressor”, page 66
l purpos
⇒ “1.2.3 Removing and installing poly V-belt without air condi‐

tioner compressor”, page 67
nf
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1.2.1 Removing and installing poly V-belt with

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tensioning element and air conditioner

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AG. Volkswagen AG d
♦ Locking pin - T10060 A- ksw
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Removing
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sulation .
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– Mark running direction of poly V-belt.

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– Turn tensioning device in direction of arrow to relieve tension
com
tio
satelettronica
on poly V-belt.
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– Align holes -arrows- and lock tensioning element in position

with locking pin - T10060 A- .
– Remove poly V-belt.
Installing
– Install in reverse order.
Note
♦ Before installing the poly V-belt, ensure that all ancillaries (al‐
ternator, air conditioner compressor) are securely mounted.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.

– Fit poly V-belt on poly V-belt pulley.

1- Crankshaft
2- Tensioning element
3- Alternator
4- Air conditioner compressor
AG. Volkswagen AG d
– Start engine and check belt running. ksw
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Danger of destruction due to reverse running direction in the
inform
case of a poly V-belt that has already run.
mer
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♦ Before removing the poly V-belt, use a piece of chalk or a

o
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felt pen to mark the running direction.
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Installing Prote
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Install in reverse order, noting the following:
Note
♦ Renew bolt for tensioning roller.

♦ Before installing the poly V-belt, ensure that all ancillaries (al‐
ternator, air conditioner compressor) are securely mounted.
– Fit poly V-belt on poly V-belt pulley:

1- Vibration damper
2- Tensioning pulley
3- Alternator
4- Air conditioner compressor
– Coat guide surfaces of tensioning roller with solid lubricating
paste with a brush; solid lubricating paste ⇒ Parts Catalogue .
– Insert tensioning roller with its pin into guide on bracket for
ancillaries.

– Tighten bolt for tensioning roller ⇒ page 63 .
AG. Volkswagen AG d
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– Check whether end of bolt for tension roller projects over ten‐
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• This ensures that the bolt has been tightened to its end stop.
hole
spec
– Start engine and check if belt runs properly.
es, in part or in w
t to the co
– Install noise insulation ⇒ General body repairs, exterior; Rep.
satelettronica
gr. 50 ; Noise insulation; Assembly overview – noise insula‐
tion .
rrectness of i
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nf
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1.2.3 Removing and installing poly V-belt

orm
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without air conditioner compressor atio

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♦ Poly V-belt repair kit with assembly tools ⇒ Parts Catalogue

r
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The poly V-belt repair kit with tools contains tool -T10367- and
illustrated instructions.
– Remove noise insulation or skid plate ⇒ General body repairs,

exterior; Rep. gr. 50 ; Noise insulation; Assembly overview -
noise insulation .
– Loosen right wheel housing liner in front area.
– Cut through poly V-belt.
– Proceed as described in illustrated instructions.
– Secure front part of right wheel housing liner again.
– Install noise insulation or skid plate ⇒ General body repairs,
exterior; Rep. gr. 50 ; Noise insulation; Assembly overview -
noise insulation .

1.3 Removing and installing tensioner for

poly V-belt
⇒ “1.3.1 Removing and installing poly V-belt tensioner”,
page 68
1.3.1 Removing and installing poly V-belt ten‐

sioner gen AG
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– Remove poly V-belt
tho ⇒ page 64 . eo
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ss
– Loosen clip -2-, raise retaining clip -1- and remove connecting
ce
le
hose on »cold side«.

un
pt
an
d
itte
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– Remove cowling together with radiator fan - V7- and right ra‐
erm
ab
diator fan - V35- ⇒ page 240 .
ility
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satelettronica
rrectness
– Unscrew securing bolts -arrows- from charge air pipe and de‐
o
cial p
tach connector -1- from charge pressure sender - G31- . f inform

mer
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– Open clip -2-, expose coolant hose -3- and remove charge air
pipe.
AG. Volkswagen AG d
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– Unscrew securing bolt -2- and remove tensioning element for
hole
satelettronica
spec
poly-V belt -1-.
es, in part or in w
t to the co
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
rrectness of i
♦ Specified torques ⇒ page 60

l purpos
♦ Install poly V-belt ⇒ page 64 .

nform
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1.4 Removing and installing bracket for an‐

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Removing
C py
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– Remove high-pressure pump ⇒ page 306 .
op Vo
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Prote AG.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
WARNING
Do not open the air conditioner refrigerant circuit.
– Remove air conditioner compressor from ancillary bracket and

secure to lock carrier.

– Unbolt idler rollers -1- and -2- and unscrew toothed belt guard
bolt -arrow-.
– Unscrew front bolt of engine bracket.
– Unscrew bolts -6…1- and remove ancillary bracket.

Installing
lowing:
♦ Note any fitted sleeves in ancillary bracket and renew missing
ones if necessary.
satelettronica
♦ Renew all bolts to be tightened with torque angle.
lkswage es n
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Ancillary bracket - specified torques and tightening sequence

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– Insert securing bolts for ancillary bracket as follows:

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♦ Bolts -1- and -2- M10 x 52.

h re
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spec
♦ Bolts -5- and -6- M10 x 60.

es, in part or in w
t to the co
♦ Bolts -3- and -4- M10 x 30.

– Tighten securing bolts for ancillary bracket in sequence
-1 … 6- in 2 stages as follows:
rrectness of i
1. Screw all bolts in to stop by hand.

l purpos
2. Tighten all bolts to 40 Nm.

nform
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3. Turn bolts -3- and -4- 45° further.

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4. Turn bolts -1, 2, 5 and 6- 90° further.

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– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;

thi
s
iva
Removing and installing alternator .

do
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rp
cum
fo
– Installing high-pressure pump ⇒ page 306 .

en
ng
t.
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op
– Screw in front bolt of engine bracket ⇒ Item 32 (page 133) . C py
t. rig
gh ht
pyri by
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by
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Prote AG.

1.5 Removing and installing engine bracket

⇒ “1.5.1 Removing and installing engine bracket, Golf and Scir‐
occo”, page 71
⇒ “1.5.2 Removing and installing engine bracket, Tiguan”,
page 73
⇒ “1.5.3 Removing and installing engine bracket, Golf Plus”, page
75
⇒ “1.5.4 Removing and installing engine bracket, Touran”,
page 78
⇒ “1.5.5 Removing and installing engine bracket, Passat, Eos and
CC”, page 80
1.5.1 Removing and installing engine bracket,

Golf and Scirocco
Removing
– Remove intake line between air mass meter - G70- and tur‐
satelettronica
bocharger.
– Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
– Remove supplementary fuel pump - V393- or fuel pump 2 -
V277- ⇒ Rep. gr. 20 ; Fuel pump: Removing and installing
fuel pump .
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!
AG. Volkswagen
♦ The engine bracket must be
lkswloosened only when theesassembly
agen AG do
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mounting has been removed.
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– Unscrew boltss a-B- and
u -C-. ac
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– Unscrew bolts -A- and remove engine mounting.

nl
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c
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Cop py
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co Vo
by lksw
cted 1. Cylinder block (pulley end)
agen
Prote AG.
– Unscrew coolant line securing bolt -arrow-.

– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing
gen AG
.liner;
VolkswRemoving
agen AG
does
and installing wheel housing linerVo.lkswa not
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nl
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ility
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– Unscrew bottom coolant line securing bolt -arrow-.
es, in part or in w
t to the co
WARNING
rrectness of i
When raising and lowering engine using support bracket -
10-222A- , ensure that no components or hoses are damaged,
l purpos
overstretched or torn off.
satelettronica
nform
mercia
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Note
on
c
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The securing bolt -1- is accessible through an aperture in the

a
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wheel housing. Raise and lower the engine via the spindle of the
p
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or
support bracket - 10 - 222 A- , if necessary, to remove or fit bolts

f
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– Unscrew securing bolts of engine bracket in sequence
lksw
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-3…1-.
AG.
– Remove engine bracket upwards.

Installing
lowing:
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
engine bracket can be stressed, causing it to break.
– Install engine bracket from above.
Note

-2- and -3-.
– Initially screw in new securing bolts finger-tight in the se‐

quence -1 … 3-.

Tightening sequence for engine bracket

– Tighten mounting bolts to the prescribed torque in the speci‐
fied sequence ⇒ Item 32 (page 133) .
– Fit assembly mounting and tighten bolts -A- first and then
-C-. Specified torque ⇒ page 37
– Move engine bracket into contact with assembly mounting.
– Start bolts -B- and tighten them. Specified torque ⇒ page 37
Further assembly is basically a reverse of the dismantling se‐
quence. During this procedure, observe the following:
satelettronica
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply and return lines (return line blue or

Tiguan
Removing
– Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing
agen
AG. and
Volkswagen AG
does
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installing fuel filter . by Vol not
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– Remove supplementary fuel pump - tV393-
ho
ri or fuel pump 2 - e or
V277- ⇒ Rep. gr. 20 ; Fuel pump:s aRemoving
u and installing ac
fuel pump . s
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un
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Note
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♦ The engine bracket must be loosened only when the assembly

rrectness of i
– Loosen bolts -B-. Unscrew bolts -A- and -C-.

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tion in
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– Unscrew bolts -B- and remove assembly mounting.

pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
satelettronica
AG. Volkswagen AG d
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– Unscrew bottom
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Note
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– Unscrew securing bolts of engine bracket in sequence s
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Installing
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quence -1 … 3-.


Golf Plus
Removing

bocharger.
fuel pump .
head .
Note

– Unscrew bolts -B- and -C-.

– Unscrew bolts -A- and remove assembly mounting.
satelettronica
AG. Volkswagen AG d
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– Unscrew coolant line securing bolt -arrow-. olksw
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WARNING

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The securing bolt -1- is accessible through an aperture

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– Install engine bracket from above. ion

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quence -1 … 3-.


1.5.4 Removing and installing engine bracket, agen

AG. Volkswagen AG d
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fuel pump .
– Unscrew bolt -arrow-, and place filler neck for windscreen
rrectness of i
washer system reservoir to one side.
l purpos
– Unscrew coolant expansion tank and place to one side (leav‐

ing coolant lines connected).
nf
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– Unscrew bolts -B- and -C-.

– Unscrew bolts -A- and remove engine mounting.


WARNING

satelettronica
Note
If necessary, raise and lower engine using spindle of support

bracket - 10 - 222 A- to remove or insert bolts -1 … 3-.

-3…1-. n AG. Volkswagen AG do
lkswage es n
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– Remove engine bracket upwards. d byV ua
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Installing auth or
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an
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Caution
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bracket securing bolts must always be followed. Otherwise the spec

engine bracket can be stressed, causing it to break. t to the co

rrectnes
Note
s o
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If necessary, raise and lower engine using spindle of support

mer
bracket - 10 - 222 A- to remove or insert bolts -1 … 3-.

atio
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Tightening sequenced bfor y V engine bracket gu
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– Tighten securing
utho bolts in specified sequence to prescribede or
torque ⇒ sItem
sa 32 (page 133) . ac
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– Fit assembly mounting and tighten bolts -A- and then -C-.
rrectne
Specified torque ⇒ page 37 .
s
s o
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– Start bolts -B- and tighten them. Specified torque ⇒ page 37 .
nform
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Passat, Eos and CC
AG.
Removing
bocharger.
Eos
fuel pump .
Passat, CC
– Unplug connector at pressure differential sender - G505- -2-,
unscrew securing bolt -1-.

– Unclip lines for pressure differential sender - G505- out of up‐

per toothed belt guard together with bracket -1-.
Note
AG. Volkswagen AG d
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The assembly mounting may only be removed if the engine V is
o
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♦ The engine bracket must be loosened only when
ss a
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– Unscrew bolts -B- and -C-. rm
ab
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– Unscrew bolts -A- and remove assembly mounting.
, is n
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es, in part or in w
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satelettronica
rrectness of i
l purpos
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a
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WARNING

Note

-2- and -3-.


-3…1-.
Installing
lowing:
Caution

AG. Volkswagen AG d
– Install engine bracket from above. lksw
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un
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-2- and -3-.
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quence -1 … 3-.
es, in part or in w
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tion in
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– Move engine bracket into contact with assembly mounting. cted agen
Prote AG.


1.6 Assembly overview - cylinder block (pul‐

ley end)
⇒ “1.6.1 Assembly overview - cylinder block (pulley end)”,
page 83
⇒ “1.6.2 Assembly overview - crankcase”,
agen
AG. Volkpage
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n AG d
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Vol ot g
1.6.1 Assembly
ris
ed overview - cylinder block (pulley
by ua
ran
t
end)
ee
tho or
s au ac
s
1 - 120 Nm + turn 90° further
ce
le
un
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❑ Renew
an
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❑ Use counterhold - 3415-
rm
ab
pe
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to loosen and tighten.
ot
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❑ Do not additionally oil or
h re
grease thread and
hole
spec
shoulder.
es, in part or in w
t to the co
❑ Turning further can be
done in several stages.
2 - Crankshaft pulley
rrectness of i
satelettronica
❑ Contact surface be‐
l purpos
tween toothed belt pul‐

ley and crankshaft must
be free from oil
nform
ercia
❑ Can only be fitted in one

m
a
position
com
tion in
r
3 - Seal
te o
thi
s
iva

do
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grease the oil seal seal‐

um
fo
en
g
ing lip.
n
t.
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❑ Before installing, re‐
C py
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gh
move oil residue from
ht
pyri by
Vo
crankshaft journal using
co lksw
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a clean cloth. Prote AG.
❑ Renewing crankshaft oil

seal - belt pulley end
⇒ page 86 .
4 - Sealing flange
❑ Must seat on dowel
pins.
⇒ page 87
❑ Install with silicone seal‐
ant - D 176 404 A2-
⇒ page 87 .
5 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 101 .
❑ Dismantling and assembling pistons and conrods ⇒ page 105
6 - Dowel pin
❑ Qty. 2
7 - Bolt

Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque
1) -1 … 10- Screw in by hand as far as stop
2) -1 … 6- Diagonally in stages; final torque
15 Nm
3) -7 … 10- 15 Nm
1.6.2 Assembly overview - crankcase
Caution

satelettronica
AG. Volkswagen AG d
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1 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 91 . AG. Volkswagen AG d
agen oes
❑ Removing and installing olksw not
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crankshaft rise
d b ara
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⇒ page 101 . utho eo
ra
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❑ Dismantling and assem‐ ss c
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bling pistons and con‐
nl
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du
rods ⇒ page 105
an
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2 - Seal
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❑ Renew
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3 - Oil filter bracket
hole
spec
es, in part or in w
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❑ Renew
❑ First fit upper left and
rrectness of i
lower right bolts and
then tighten all 4 bolts in
l purpos
diagonal sequence.
satelettronica
5 - Bracket
nform
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6 - 10 Nm
m
at
om
io
7 - Union
n
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❑ For thermostat
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8 - 15 Nm
um
for
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9 - O-ring
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10 - Thermostat
c by lksw
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❑ Observe installation po‐
sition, Removing and in‐
stalling thermostat
⇒ page 219 .
❑ Checking: heat thermostat in water.
❑ Begins to open at approx. 85 °C
❑ Ends at approx. 105 °C.
❑ Opening lift min. 7 mm
12 - Bracket
❑ For ancillaries
❑ Renew
14 - Poly V-belt tensioning element
15 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 404 A2- .
16 - 15 Nm

AG. Volkswagen AG d
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1.7 d bRenewing crankshaft oil seal - belt pulley end
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Special tools
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nf
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n in
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satelettronica
or
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Prote AG.
♦ Seal puller - 3203-

♦ Counter-hold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
– Remove toothed belt ⇒ page 133 .

– Remove crankshaft pulley. To do this, lock pulley using coun‐

terhold - 3415- .
– To guide oil seal extractor - 3203- , screw centre bolt into
crankshaft by hand to stop.
– Unscrew the inner part of oil seal extractor 2 turns (approx. 3
mm) from the outer part and lock in position with the knurled
screw. en AG. V
olkswagen AG
ag does
ol ksw not
– Oil threaded head of seal bextractor.
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– Screw oil seal extractor forcibly as far as possible into oil seal.
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– Loosen knurled screw and turn inner part against crankshaft
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until the oil seal is pulled out.
wit
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Installing
spec
t to the co
Note
satelettronica
rrectne
Do not be additionally oil or grease the oil seal sealing lip.
s
– Remove oil residues from crankshaft journal with a clean cloth.
s o
cial p
f inform
– Fit guide sleeve - T10053/1- onto crankshaft journal.
mer
atio
m
– Slide seal over guide sleeve onto crankshaft journal.

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– Press oil seal in as far as stop with press sleeve - T10053- and
central bolt.
– Install crankshaft pulley.
– Specified torque of new centre bolt ⇒ Item 2 (page 132) .
– Install and tension toothed belt ⇒ page 133 .
1.8 Removing and installing sealing flange on pulley end

Special tools and workshop n AG. Volkswagen AG do

equipment required lkswage es n
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mer
atio
satelettronica
om
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Prote AG.

♦ Hand drill with plastic brush
♦ Silicone sealant - D 176 404 A-
♦ Scraper
Removing

– Remove crankshaft pulley. Lock toothed belt pulley using

counterhold - 3415- .
– Drain engine oil.
– Remove sump ⇒ page 178 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove residual sealant on sealing flange using a rotating

plastic brush (wear protective goggles).
– The sealing surfaces must be free of oil and grease.
Installing
Note
satelettronica
♦ Observe use-by-date of sealant.
♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).
Note
AG. Volkswagen AG d
agen oes
ksw
♦ The sealant bead must by V be no thicker than 2…3 mm.oExcess
ol n t
gu
sealant can find ritsise way into the sump and block the strainer
d ara
nte
in the suction uline
tho or drip on the sealing surface of the crank‐e or
shaft seal. ss a ac
ce
le
♦ Before applying the sealant bead, cover the sealing surface of

un
pt
an
d
the oil seal with a clean cloth.

itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

– Apply silicone sealant bead as shown to clean sealing surface

of sealing flange.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
When fitting sealing flange with oil seal installed use guide sleeve
- T10053/1- .
– Tighten securing bolts of sealing flange to 15 Nm diagonally.

– Install crankshaft pulley.
– Specified torque of new centre bolt ⇒ Item 2 (page 132) .
– Install sump ⇒ page 178 .
Note
Leave the sealant to dry for approx. 30 minutes after assembly.

Only then fill with engine oil.
satelettronica
Install toothed belt and adjust the valve timing ⇒ page 133 .
AG. Volkswagen AG d
agen oes
olksw not
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hole
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es, in part or in w
t to the co
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mercia
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tion in
r
te o
thi
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cum
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 91
⇒ “2.2 Removing and installing flywheel”, page 92
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 93
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ Renew
❑ 60 Nm +90°
2 - Dual-mass flywheel
⇒ page 92
satelettronica
position only
3 - Sender wheel
❑ For engine speed send‐
er - G28-
4 - Engine speed sender -
G28-
⇒ page 398
5 - 5 Nm AG. Volkswagen AG d
agen oes
olksw not
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6 - Dowel pin d b ara
rise nte
❑ Qty. 2 autho eo
ra
ss c
7 - Adapter
ce
e
nl
pt
du
❑ Do not damage or bend

an
itte
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when assembling
erm
ab
⇒ page 92 .
ility
ot p
wit
, is n
8 - Sealing flange on flywheel

h re
end
hole
spec
❑ With shaft seal

es, in part or in w
t to the co
❑ Renewing ⇒ page 93
9 - Bolt
rrectness of i
❑ Specified torque and

tightening sequence
l purpos
⇒ page 92
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
2. Cylinder block, gearbox end 91

Install intermediate plate.

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.
Sealing flange on flywheel pulley end - specified torque and tight‐

ening sequence
Stag Bolts Specified torque
e
satelettronica
15 Nm
2.2 Removing and installing flywheel

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
Removing
, is n
h re
hole
• Gearbox is removed.
spec
es, in part or in w
t to the co
Caution
Risk of damage to dual-mass flywheel.

rrectness of i
♦ Screw out bolts -B- not with an air wrench or power impact
l purpos
wrench but by hand.

♦ When unscrewing the bolts, make sure that the bolt heads
nform
ercia
do not touch the dual-mass flywheel.

m
at
om
♦ Rotate dual-mass flywheel -A- so that bolts -B- align cen‐

on
c
in t
trally with the holes -arrows-.

or
his
ate
do
priv
cum
for
en
ng
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Cop py
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rig ht
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92
by lksw
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Prote
Rep. gr.13 - Crankshaft group
AG.
– Insert counterhold - 3067- in hole in cylinder block -item B- and

loosen bolts for dual-mass flywheel.
– Unscrew bolts and remove dual-mass flywheel.
Installing
• Specified torque
⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
91 .
Note
Renew dual-mass flywheel bolts.
– Insert counterhold -sw3067-

agen in hole in cylinder
AG. Volkswagen AG d block -item A-.
oes
olk not
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c
ss
2.3 Removing and installing sealing flange on gearbox side
ce
e
nl
satelettronica
pt
du
an
itte
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erm
ab
ility
ot p
equipment required
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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ng
t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.

♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d

agen oes
♦ Tool insert 24 mm - V.A.G 1332/11- olksw not
V gu
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♦ Depth gauge aut
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♦ 3 hexagon bolts M6 x 35 mm
ce
le
un
pt
an
d
♦ 2 hexagon bolts M7 x 35 mm
itte
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erm
ab
⇒ “2.3.1 Pressing out sealing flange with sender wheel”,
ility
ot p
page 94
wit
is n
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ole,
⇒ “2.3.2 Pressing in sealing flange with sender wheel”,
spec
page 95
t to the co
2.3.1 Pressing out sealing flange with sender
wheel
rrectne
– Remove gearbox. ⇒ Rep. gr. 34 ; Removing and installing
gearbox
ss o
cial p
f
– Remove flywheel.
inform
mer
– Remove intermediate plate.
atio
satelettronica
m
– Turn crankshaft to TDC No. 1 cylinder as shown.

o
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c
i
or
n thi
e

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Note Cop
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♦ For reasons of clarity, the work is performed with the engine pyri by
Vo
o
by c
removed.
lksw
cted agen
Prote AG.
♦ The procedure is identical whether the engine is installed or
removed.
– Remove engine speed sender - G28- -arrow-.

– Unscrew securing bolts of sealing flange.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together with 3 x M6 × 35 mm bolts.
– Screw in 3 M6 x 35 mm bolts into threaded holes of sealing

flange -arrows-.
– Screw bolts (max. 180° per bolt) into sealing flange alternately
in order to press it and the sender wheel of crankshaft togeth‐
er.

2.3.2 Pressing in sealing flange with sender

wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
. Volkswagen AG
gen AG
♦ Do not separate or turn the sealing flange kand
swa sender wheel does
not
Vol
after removal from packaging. ed by gu
ara
ris nte
o
♦ The sender wheel is held in its ainstallation
uth position on the as‐ eo
ra
sembly device - T10134- by asslocating pin. c
ce
le
un
pt
♦ Sealing flange and oil seal form one unit and must only be
an
d
itte
renewed together with the sender wheel.
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erm
ab
ility
♦ The assembly device - T10134- is held in its position relative
ot p
to the crankshaft by a guide pin inserted into a hole in the
wit
is n
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crankshaft.
ole,
spec
satelettronica
Assembly tool - T10134-
t to the co
A - Clamping surface
rrectne
B - Hexagon nut
C - Assembly housing
ss o
D - Locating pin
cial p
f inform
E - Hexagon socket head bolt
mer
atio
m
F - Guide pin for diesel engines (black knob)

o
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c
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or
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G - Guide pin for petrol engines (red knob)
thi
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1.) Mounting seal with sender wheel on assembly tool - T10134-

p
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– Screw on hexagon nut -B- until just before it touches clamping . Cop py
surface -A- of threaded spindle.
t rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press the assembly housing -C- downwards until it lies on
hexagon nut -B-, -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.

– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean
level surface.
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– Push sealing lip support ring -A- downwards in direction of ar‐

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– Upper edge of sender wheel and front edge of sealing flange

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– Place sealing flange with front side facing downwards onto

assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains
satelettronica
fixed in assembly tool.
2.) Mounting assembly tool - T10134- with sealing flange on

crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder
– Screw hexagon nut -B- on until it reaches end of threaded

spindle.
– Press threaded spindle of assembly tool AG-. T10134-
VolkswageninAG
direction
of arrow until hexagon nut -B-olies agen
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– Align flat side of assembly
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– Secure assembly tool - T10134- to crankshaft flange with hex‐

agon socket head bolts -A-.

t to the co
Note
rrectne
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
s
prox. 5 full turns).

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– Screw in 2 M7 × 35 mm bolts -A- to guide sealing flange into

cylinder block.
3.) Bolting assembly tool - T10134- onto crankshaft flange
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sealing lip support ring -B- touches crankshaft flange -A-.
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– Push guide pin for diesel engines (black knob) -D- into hole in
an
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crankshaft. This ensures that the sender wheel reaches its fi‐
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Note
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Do not insert the guide pin for petrol engines (red knob) -F- into
the threaded hole of crankshaft.
– Tighten hexagon socket head bolts of assembly tool finger- rrectness of i

tight.
l purpos
– Screw hexagon nut -E- onto threaded spindle by hand until

hexagon nut -E- lies on assembly housing -C-.
nform
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4.) Pressing sender wheel onto crankshaft flange using assembly

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tool - T10134-
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– Tighten hexagon nut of assembly tool - T10134- with torque

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wrench - V.A.G 1331- and tool insert - V.A.G 1332/11- to

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After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
5.) Checking sender wheel installation position on crankshaft
– Screw on the hexagon nut -E- until it reaches the end of the
threaded spindle.
– Unscrew the 2 bolts -A- from cylinder block.
– Unscrew the three knurled screws -B- out of sealing flange.

– Unscrew hexagon socket head bolts -A- and remove assem‐

bly tool - T10134- .
– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
satelettronica
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– Place caliper gauge on crankshaft flange.
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– Measured distance -a- between crankshaft flange and sender
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wheel.
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If dimension -a- is too small:
hole
spec
– Re-press sender wheel ⇒ page 99 .
es, in part or in w
t to the co
If dimension -a- is achieved:
– Tighten new sealing flange securing bolts diagonally and al‐
rrectness of i
ternately to 15 Nm.
l purpos
nf
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– Install engine speed sender - G28- -arrow- and tighten secur‐ orm
ing bolt to 5 Nm.
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– Install intermediate plate.

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– Install flywheel with new bolts. Tighten securing bolts to 60 Nm

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– Bolt assembly tool - T10134- to crankshaft flange with hexa‐

gon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Push the assembly tool - T10134- against the sealing flange
by hand.
– Screw hexagon nut -E- onto threaded spindle by hand until

hexagon nut -E- lies on assembly housing -C-.
satelettronica
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– Tighten hexagon nut of assembly tool - T10134- oris with torque
e nte
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wrench - V.A.G 1331- and tool insert - V.A.G
aut 1332/11- to
h
ra
40 Nm. ss c
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– Check sender wheel installation position on the crankshaft
an
d
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⇒ page 98 .
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If dimension -a- is still too small:
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– Tighten hexagon nut to 45 Nm using assembly tool - T10134- .
h re
hole
spec
– Check sender wheel installation position on the crankshaft
es, in part or in w
⇒ page 98 .
t to the co
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3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 101
⇒ “3.3 Crankshaft dimensions”, page 104
⇒ “3.2 Renewing needle bearing in crankshaft”, page 101
3.1 Assembly overview - crankshaft
1 - Bearing shell
❑ For bearings 1, 2, 4 and
5.
❑ Do not interchange
used bearing shells n AG. Volkswagen AG do
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❑ Bearing cap 3 with re‐
t to the co
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❑ Bearing shell retaining
lugs in cylinder block
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and bearing caps must

align.
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4 - Thrust washer
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❑ For bearing cap 3
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❑ Note fixing arrangement
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5 - Needle bearing
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❑ Only vehicles with dual
o
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⇒ page 101
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6 - Crankshaft
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❑ Axial clearance new:

0.07 to 0.17 mm; wear
limit: 0.37 mm
❑ Check radial clearance with Plastigage
❑ New: 0.03 … 0.08 mm; Wear limit 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 104 .
7 - Thrust washer
❑ For cylinder block, bearing 3
3.2 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
3. Crankshaft 101
AG. Volkswagen AG d
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♦ Counter support, e.g. KUKKO 22-1 by -V VAS 251 621-
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♦ Internal puller - VAS 251 635-
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♦ Pin - VW 207 C- cted agen
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Condition:
• The front edges of the inner puller must be free of chips.
• Gearbox has been removed.

Pulling out needle roller bearing

– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
satelettronica
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
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If the needle bearing is inadvertently driven in too far, it must be

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renewed because it will be damaged when it is pulled out again.

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agen 3. Crankshaft
AG. Volkswagen AG d
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3.3 Crankshaft dimensions by
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main journal ∅ journal ∅
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Basic dimension 54.00 -0.022 50.90 -0.022
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4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 105
⇒ “4.2 Separating new conrod”, page 109
⇒ “4.3 Measuring piston projection at TDC”, page 109
⇒ “4.4 Checking radial clearance of conrods”, page 111
4.1 Assembly overview - pistons and con‐

rods
⇒ “4.1.1 Assembly overview - pistons and conrods”, page 105
⇒ “4.1.2 Piston and cylinder dimensions”, page 108
⇒ “4.1.3 Bearing shells - installation position”, page 108
4.1.1 Assembly overview - pistons and conrods
satelettronica
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 106 .
❑ Checking ring-to-groove AG. Volkswagen AG d
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❑ Top and centre: Com‐ rised
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tion and cylinder num‐

hole
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t to the co
❑ Installation position and

allocation of piston to
cylinder ⇒ page 108 .
rrectness of i
❑ Arrow on piston crown

points to belt pulley end.
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❑ Install using piston ring

clamp.
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❑ If piston skirt is cracked,

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❑ Checking piston projec‐

r
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tion at TDC
thi
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⇒ page 109 .
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❑ Remove and install using drift - VW 222- .
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4. Pistons and conrods 105

4 - Retaining ring
5 - Connecting rod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
❑ Separate new conrod ⇒ page 109 .
6 - Bearing shell
❑ Note installation position ⇒ page 108
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Ensure firm seating
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
satelettronica
❑ Checking cylinder bores ⇒ page 107 .
❑ Piston and cylinder dimensions ⇒ page 109 .
8 - Conrod bearing cap
❑ Observe installation position lkswage es n
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❑ Due to the cracking method used to separate ed the bearing cap from the conrod during
by ua
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caps only fit in one position and only onthothe
r associated conrod.
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9 - Oil spray jet ss c
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❑ For piston cooling
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10 - 25 Nm
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11 - Conrod bolt, 30 Nm + 90° further
hole
❑ Renew spec
es, in part or in w
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❑ Oil threads and contact surface
❑ Use old bolt for measuring radial clearance.
rrectness of i
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Checking piston ring gap

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♦ Feeler gauge
– Push piston ring squarely from above down into cylinder bore
to approx. 15 mm from bottom end of cylinder.

Piston ring New Wear limit

dimensions in mm (mm) (mm)
1st compression ring 0.20 … 0.40 1.00
2nd compression ring 0.20 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00
Checking ring-to-groove clearance
satelettronica
♦ Feeler gauge
– Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm (mm) (mm)
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Checking cylinder bores
AG. Volkswagen AG d
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♦ Cylinder gauge 50 …100 mm

inform
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– Take measurements at 3 positions in both lateral direction

atio
-A- and longitudinal direction -B-. Difference between actual

om
and nominal diameter max. 0.10 mm.

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4. Pistons and conrods
agen
Prote AG.
AG. Volkswagen
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Cylinder bores must not be measured when the cylinder block is
erm
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secured to engine and gearbox support - VAS 6095- , as meas‐
ility
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urements may be incorrect.
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Checking piston es, in part or in w
t to the co
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
ton pin axis with a 75 to 100 mm external micrometer.
• Maximum deviation from nominal dimension: 0.04 mm.
rrectness of i
Nominal dimension
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Note
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at
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ion
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If piston skirt is cracked, renew piston.
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Installation position and allocation of piston to cylinder

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4.1.2 Piston and cylinder dimensions

Honing dimension Piston Ø Cylinder bore Ø
(mm) (mm)
Basic dimension 80.961) 81.01
• 1)Dimensions include coating (thickness 0.02 mm). The
coating will wear down.
4.1.3 Bearing shells - installation position

Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Distance -a- must be identical on both sides.

4.1.4 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
Basic di‐ mm 80.96 81.01
mension
4.2 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark allocation of conrod to cylinder.
– Lightly clamp conrod in vice using protective aluminium jaws,
as shown in figure.
Note
♦ Only clamp the conrod

wage
n Alightly
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♦ Conrod isedclamped
by below the dashed line. ara
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– Unscrew
ss
a both bolts -arrows- about 5 turns. c
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nl
pt
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erm
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– Using a plastic hammer, carefully knock against conrod bear‐

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ing cap in -direction of arrow- until it is loose.

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4.3 Measuring piston projection at TDC

on
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4-cylinder common rail engine (2.0 l, EA189 Gen II) - Edition 06.2019 ss
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♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-

♦ Measuring plate -VW 385/17- from universal measuring tool -
VW 385-
♦ Dial gauge - VAS 6079-
Test sequence
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in the illustration.

– Measure the projection of each piston at the two points marked

with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
Piston projection at TDC must be measured when new pistons or
a short engine is installed. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
AG. Volkswagen AG d
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♦ To measurehothe piston projection at top dead centre, turn
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urement, use the largest dimension for selecting the gasket.
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Piston projection Identification
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0.91 to 1.00 mm 1
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satelettronica
1.11 to 1.20 mm 3
rrectness of i
4.3.1 Cylinder head gasket identification
l purpos
♦ Part No. = arrow 1

♦ Holes = arrow 2 nform
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♦ Production control code = arrow 3 (can be disregarded)

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♦ Different thicknesses of cylinder head gasket are fitted de‐

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pending on the piston projection. When the seal is renewed,
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♦ Piston projection at TDC must be determined when installing
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new pistons or a short engine ⇒ page 109 .
Prote AG.
4.4 Checking radial clearance of conrods

♦ Plastigage
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm without turning
further angle and without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:

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• Wear limit: 0.08 mm. ss
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– Renew conrod bolts.
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15 – Cylinder head, valve gear

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⇒ “1.4 Assembly overview - cylinder head cover”, page 127
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⇒ “1.3 Removing and installing cylinder head cover”, page 124
ility
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⇒ “1.5 Removing and installing vacuum pump”, page 129
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⇒ “1.6 Checking compression”, page 130
spec
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1.1 Assembly overview - cylinder head
rrectness of i
1 - Cylinder head gasket
❑ Renew
l purpos
❑ Cylinder head gasket
satelettronica
identification
nform
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⇒ page 115
m
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❑ Renew coolant and en‐
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gine oil after replacing.
n
c
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2 - 10 Nm
at
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❑ Insert with locking fluid,
um
for
locking fluid ⇒ Electron‐
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ic parts catalogue . t. Cop py
rig
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3 - Hall sender - G40- yri
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❑ For camshaft position. cted agen
Prote AG.
⇒ page 398
4 - Cylinder head
⇒ page 115
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Check for distortion
⇒ page 114 .
❑ Must not be reworked.
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head on cylinder
block are fitted.
❑ Renew coolant and en‐
gine oil after replacing.
5 - Washer
6 - Cylinder head bolt
❑ Renew
❑ Sequence when loosening ⇒ page 114 .
1. Cylinder head 113

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4-cylinder common
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7 - Oil pressure switch - F1- , 20 Nm
un
pt
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❑ Switch pressure 0.3 to 0.6 bar itte
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❑ Checking ⇒ page 193
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8 - Seal
spec
❑ Renew
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9 - 20 Nm
10 - Engine lifting eye
rrectne
11 - Seal
s
❑ Renew
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12 - 20 Nm
form
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13 - Seal
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❑ Renew
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14 - Vacuum pump
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15 - 10 Nm
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❑ For coolant hoses
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❑ With coolant temperature sender - G62-
17 - 9 Nm
18 - Seal
❑ Renew
19 - 20 Nm
20 - Engine lifting eye
Observe sequence when loosening cylinder head bolts

– Slacken cylinder head bolts in the sequence -1 … 10-.
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
• Max. permissible distortion: 0.1 mm
Note
Cylinder heads for TDI engines must not be reworked.
114 Rep. gr.15 - Cylinder head, valve gear

Cylinder head gasket identification

1- Part number
2- Holes
3- Ignore AG. Volkswagen AG d
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Different thicknesses of cylinder head gasket are fitted depending s
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on the piston projection. If only cylinder head gasket is removed,
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install a new cylinder head gasket with same identification.
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Cylinder head - specified torque and sequence
satelettronica
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Renew bolts for cylinder head.
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Stage Bolts Specified torque/turning further angle

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1) -1 … 10- 30 Nm
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2) -1 … 10- 50 Nm
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1.2 Removing and installing cylinder head

Special tools and workshop AG. Volkswagen AG d

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equipment required Volksw
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♦ Guide pin - 3070-

♦ Diesel injection pump locking pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counter-hold tool - T10051-
♦ Puller - T10052-
♦ Socket XZN 10 - T10385-

satelettronica
AG. Volkswagen AG d
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nform
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Note
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♦ Read anti-theft radio code as the next work step requires the
p
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or
earth strap of the battery to be disconnected.

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♦ All cable ties which are opened or cut through when cylinder
C py
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head is removed must be renewed/replaced in the same po‐
ht
pyri by
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sition when the cylinder head is installed.
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WARNING

conditions:
restored.
hot components. agen
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Removing tho or
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– With ignition battery earth strap. ⇒ ss
switched off, disconnect
ce
le
Electrical system; Rep. gr. 27 ; Alternator; Removing and in‐

un
pt
an
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stalling alternator .
itte
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ab
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spec
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
satelettronica
27 ; Battery; Removing and installing battery .
t to the co
– Remove cowling together with radiator fan - V7- and right ra‐
diator fan - V35- ⇒ page 240 .
rrectne
– Remove connecting hose on »cold side«
⇒ Item 13 (page 253) of charge air cooler.
– Remove cylinder head cover ⇒ page 124 . ss o
cial p
f inform
– Pull off connector from throttle valve control element - J338-

mer
-2-.
atio
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c
– Unscrew bolt from oil dipstick connection -4-.

i
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– Disconnect vacuum line from vacuum pump.

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Cop py
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by
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– Unscrew bolts -2, 5- and -arrows-.

– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
– Loosen hose clip -3- and remove left air pipe.

– Unscrew bolts -arrows- and remove pulsation damper -2-.

sulation .
– Disconnect electrical connector -4- from coolant temperature
sender - G62- .
– Pull coolant hoses off connection. To do this, loosen hose clips

-1- and -2-.
satelettronica
AG. Volkswagen AG d
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– Disconnect electrical connector -1- from oil pressure switch -

un
pt
an
d
F1- .
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– Unscrew bolt -arrow-.
ility
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– Pull off vacuum hose -2-.
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Remove electrical connector -3- from bracket and disconnect.
form
mer
– Free electrical lines on turbocharger.

atio
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c
i
or
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sd
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Cop py
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lk swage es n
CC 2010 ➤ , Eos d2006 by
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ara ➤ , Passat 2011 ...
4-cylinder common orise
rail engine (2.0 l, EA189 Gen II) - Edition
nte 06.2019
eo
uth ra
a c
ss
– Unscrew securing bolts -arrows- from charge air pipe and de‐
ce
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nl
tach connector from charge pressure sender - G31- -1-.
pt
du
an
itte
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ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
– Open clip -2-, expose coolant hose -3- and remove charge air
for
en
g
satelettronica
pipe.
n
t.
yi Co
Cop py
t. rig
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yri
Caution
p by
co Vo
by lksw
cted agen
Prote AG.
Ensure that flexible joint of connecting pipe is not bent and
stretched. There is a danger of cracking.
– Remove connecting pipes -A- for exhaust gas recirculation

using bit - T10385- .

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(2.0 l, EA189 Gen II) - Edition 06.2019
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– au
Unscrewsssecuring nuts -arrows- of particulate filter bracket ac
r
-A- on crankcase.
ce
e
nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew union nut -2- and remove bolt -3-.
nf
ercia
orm
m
atio
om
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or c
thi
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
– Unscrew bolt -arrow- from toothed belt guard at rear.

– Loosen connecting clamp between turbocharger and particu‐
late filter.
– Unscrew securing bolt of bracket on cylinder head -arrow- and

push particulate filter to one side.

– Detach connector for Hall sender - G40- -arrow-.

– Remove toothed belt from camshaft ⇒ page 133 .
– Remove toothed belt pulley of camshaft and pull camshaft hub
off using puller - T10052- .
– Unscrew securing nut of toothed belt tensioning roller.
– Loosen cylinder head bolts in sequence -1 to 10-.
Note
♦ A second mechanic is required for the removal of the cylinder

head.
♦ The toothed belt tensioning roller is pulled off the stud when
satelettronica
the cylinder head is lifted out.
♦ The oil return line of the turbocharger is pulled out of the sup‐ .V olkswagen AG
gen AG does
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port when the cylinder head is lifted out. by
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– Lift up cylinder head on gearbox side first and guide
ut out of ra
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toothed belt guard. Make sure that toothed belt tensioner does
s
ce
e
not fall down.

nl
pt
du
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itte
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– Place cylinder head to one side so that oil return line is not
erm
ab
bent. Place piece of wood under exhaust manifold.
ility
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Installing
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
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c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

Note
♦ Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
♦ Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
♦ Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the tur‐
bocharger or the conrod bearings. gen AG
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d
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– Only remove sealant residue from ise cylinder head and cylinder
d ara
nte
or
block using scraper - VAS 852uth005- or a commercially availa‐ eo
ra
ble ceramic glass scraper. ss a c
ce
e
nl
• The sealing surfaces must not be damaged.
satelettronica
pt
du
an
itte
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• There must be no oil or coolant in the bolt pockets.
erm
ab
ility
ot p
• Do not remove new cylinder head gasket from packaging until
wit
, is n
it is ready to be fitted.
h re
hole
spec
• If a new cylinder head is installed, contact surfaces between
es, in part or in w
roller rocker fingers and running surface of cam must be oiled.
t to the co
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
rrectness of i
gasket.
l purpos
• Turn the crankshaft carefully at least 2 rotations to ensure that

none of the valves make contact when the starter is operated.
nform
ercia
• When the cylinder head or cylinder head gasket is renewed,

the entire coolant and the engine oil must be changed.
m
at
om
io
– Remove any loose remains using a lint-free cloth.

n
c
in t
or
his
e
– Before fitting cylinder head, remove crankshaft stop -

at
do
riv
T10050- , and turn crankshaft in opposite direction of engine

p
cum
or
rotation until all pistons are nearly uniformly below TDC.

f
en
ng
t.
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op py
– Note cylinder head gasket identification:
. C rig
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rig by
py
1- Part number
co Vo
by lksw
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Prote AG.
2- Holes
3- Ignore
– Cylinder head gasket must lie with identification facing up‐
wards.

– To centre, screw guide pins - 3070- into outer threaded holes

on intake side.
Note
Tensioning roller must be pushed onto studs when fitting cylinder

head.
– Fit cylinder head, start 8 cylinder head bolts and hand-tighten.

– Remove guide pins through bolt holes using removal tool from
3070 and install cylinder head bolts.
– Tighten cylinder head in 4 stages in sequence shown as fol‐

lows:
1- Tighten initially with torque wrench:
AG. Volkswagen AG d
Stage I = 30 Nm lksw
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Step II = 50 Nm ised ara
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2- Turn further with rigid spanner: aut ra
satelettronica
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Stage III = 90°
e
nl
pt
du
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itte
Stage IV = 90°
y li
erm
ab
ility
– Secure rear toothed belt guard on cylinder head.
ot p
wit
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– Install hub and camshaft sprocket.
h re
hole
spec
– Lock camshaft and high-pressure pump with diesel injection
es, in part or in w
pump locking pin - 3359- .
t to the co
– Turn crankshaft to TDC in direction of engine rotation and lock
rrectness of i
crankshaft with crankshaft stop - T10050- .
l purpos
– Fit toothed belt ⇒ page 133 .

Continue installation in reverse order of removal. During this pro‐
nf
ercia
cedure, observe the following: orm

m
– Install cylinder head cover ⇒ page 124 .

atio
om
n in
c
– Install poly V-belt ⇒ page 60 .

or
thi
te
sd
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– Carry out road test and read event memory ⇒ Vehicle diag‐
f
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t.
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nostic tester .
Co
Cop py
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1.3 Removing and installing cylinder head
op Vo
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cover
Prote AG.
⇒ “1.3.1 Removing and installing cylinder head cover”,

page 124
⇒ “1.3.2 Renewing seals for injectors”, page 126
1.3.1 Removing and installing cylinder head

cover
Removing

– Disconnect electrical connector -2- at pressure differential

sender - G505- .
– Unscrew bolt -3-, pull pressure differential sender - G505- from
bracket -arrow- and lay aside.
– Release clips -arrows- and press upper toothed belt guard

aside to the right.
– Remove injectors and fuel rail ⇒ page 268 .
satelettronica
AG. Volkswagen AG d
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olksw not
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d b ara
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– Remove crankcase breather hose -1- from cylinder head cov‐

nl
pt
du
an
er; press release buttons for this.
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Disconnect electrical connector -arrow- at position sender for

nform
ercia
charge pressure positioner - G581- .

m
at
om
– Remove vacuum lines from bracket on cylinder head cover.

ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Loosen and unscrew bolts for cylinder head cover in the se‐
quence -6 to 1-.
– Remove cylinder head cover.
Installing
Note
♦ Renew gasket for cylinder head cover and bolts for cylinder
head cover if damaged or leaking.
satelettronica
♦ Renew grommets and seals for injectors if damaged or leak‐
ing.
– Tighten bolts for cylinder head cover ⇒ page 129 .
– Ensure that cylinder head cover is correctly clipped to toothed

belt guard -arrows-.
Note
agen
AG. Volkswagen AG d
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Installation positionriseillustrated with camshaft sprocket removed.
d b ara
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– Check clearance
ss between hub and toothed belt guard. c
ce
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nl
pt
– Install coolant return line.

du
an
itte
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erm
– Install intake pipe ⇒ page 241 .

ab
ility
ot p
– Install fuel rail and injectors ⇒ page 268 .

wit
, is n
h re
– Install pressure differential sender - G505- .

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.3.2 Renewing seals for injectors

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
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♦ Follower - 3390- byV
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nl
pt
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ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Procedure
– Remove cylinder head cover ⇒ page 124 .
l purpos
– Press out seal for injector using carrier - 3390- and short ex‐
nf
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tension -1- upwards from below.
orm
m
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– Press in new seal for injector using carrier - 3390- and short
c by lksw
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extension -1- from top to stop. Prote AG.
1.4 Assembly overview - cylinder head cov‐

er
Caution


1 - Seal
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 124
3 - O-ring
❑ Renew agen
AG. Volkswagen AG d
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4 - Hose d by V gu
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❑ For crankcase ventila‐ uthor eo
tion. ss a ra
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❑ Press release buttons to
ce
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un
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detach
an
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5 - Sealing bushing
pe
ility
ot
❑ For fuel rail.
wit
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❑ Renew if damaged or
hole
spec
leaking
es, in part or in w
t to the co
6 - Bracket
satelettronica
❑ For electrical cables
rrectness of i
7 - Grommet
l purpos
8 - Clamping piece
9 - 8 Nm
nform
ercia
10 - High-pressure accumula‐
m
tor (rail)
a
com
tion in
❑ Comply with rules for
r
te o
thi
cleanliness ⇒ page 7
s
iva
do
❑ Do not attempt to re‐
r
rp
cum
shape high-pressure
fo
en
ng
lines.
t.
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Cop py
❑ Installing high-pressure
t. rig
gh ht
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lines ⇒ page 281 . p by
co Vo
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11 - 22 Nm Prote AG.

❑ Renew
13 - Fuel return line
14 - O-ring
❑ Renew
15 - Injector
❑ Comply with rules for cleanliness ⇒ page 7
16 - O-ring
❑ Renew
17 - Heat shield seal
❑ Renew
18 - Seal
❑ for injector

19 - Cap
20 - Seal
❑ For sealing cover
21 - Grommet
22 - Bracket
23 - Bolt
❑ Renew gasket if damagedAG. Volkswagen AG d
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❑ Specified ytorque not ⇒ page 129
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Cylinder - specified torque and tightening sequence
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– Tighten bolts for cylinder head cover in the sequence
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-1 … 6- to 9 Nm.
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1.5 Removing and installing vacuum pump

nform
mercia
at
DANGER!
om
ion
c
in t
or
The vacuum pump may, under no circumstances, be disman‐

his
ate
tled as the vacuum part could otherwise malfunction. This

do
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would result in failure of the brake servo.

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Removing gh ht
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– Remove air filter housing ⇒ page 293 . Prote
cted AG.
agen
– Detach vacuum line -1- from vacuum pump -2-.

– Unscrew securing bolts of charge air pipe
⇒ Item 4 (page 253) .
– Push charge air pipe down slightly to gain access to rear
threaded connection of vacuum pump.

– Remove securing bolts -arrows-.

– Remove vacuum pump -2- from cylinder head.
Installing
Volkswagen AG
Installation is carried out in the reverse order. When installing,
agen
AG. does
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note the following: by
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♦ Ensure that vacuum pump coupling seats properly in cam‐
an
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shaft.
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♦ The seal must be renewed.
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– Install vacuum pump and tighten securing bolts to 10 Nm.
spec
es, in part or in w
– Connect brake servo vacuum line -1- to vacuum pump.
t to the co
1.6 Checking compression
rrectness of i
l purpos
satelettronica
♦ Jointed spanner - 3220-
nform
mercia
at
om
ion
c
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or
his
ate
do
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Prote AG.
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-

Prerequisites for check
• Engine oil temperature min. 30 °C
Test sequence
– Pull connectors off the injectors.
– Remove sheathed glow plugs using U/J extension and socket
- 3220- ⇒ page 395 .
– Screw in adapter - V.A.G 1763/8- in place of the glow plugs.
– Check compression using compression tester - V.A.G 1763- .

Note
Using the compression tester ⇒ Operating manual.
– Start engine until tester shows no further pressure increase.

Compression pressures:
New: 25…31 bar
Wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs with the U/J extension and 10 mm socket -
3220- ⇒ page 395 .
– Read engine control unit event memory ⇒ Vehicle diagnostic
tester .
Note
satelettronica
Events will have been stored in the event memory because the
connectors for injectors have been disconnected. Therefore, read
event memory and delete if necessary.
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2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 132
⇒ “2.2 Removing and installing toothed belt”, page 133
2.1 Assembly overview - toothed belt
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 133 .
❑ Renew
❑ Use counterhold - 3415-
satelettronica
to loosen and tighten.
grease the threads and
shoulder.
❑ Turning further can be
done in several stages.
3 - Crankshaft pulley
4 - 20 Nm
5 - Idler roller
Note
Renew stud for idler
olks
wpulley
age only if es n
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damaged. Specified
d by V torque for stud: ua
ran
15 Nm. orise tee
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7 - Tensioning pulley
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❑ Remove engine bracket

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install ⇒ page 71 .
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Note
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Renew stud for tensioning roller only

if damaged. Specified torque for
stud: 15 Nm.
rrectne

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9 - Camshaft sprocket
f inform
mer
10 - 20 Nm
atio
m
11 - 100 Nm
o
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12 - Hub
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❑ Use counterhold - T10051- to loosen and tighten.

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❑ To remove, use puller - T10052- .

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132
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Rep. gr.15 - Cylinder head, valve gear
13 - Rear toothed belt guard

14 - 20 Nm
15 - 10 Nm
❑ Renew
16 - Idler roller
❑ Renew
18 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
19 - 95 Nm
20 - Toothed belt pulley on high-pressure V
pump
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21 - 20 Nm olksw not
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22 - Coolant pump rise nte
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❑ Removing and s auinstalling ⇒ page 218 ra
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23 - 15 Nm
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24 - Toothed belt guard upper part
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25 - Toothed belt guard lower part
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26 - Toothed belt guard centre part
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27 - 10 Nm
❑ Renew t to the co
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❑ Renew
29 - Belt pulley and vibration damper
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❑ Offset holes make assembly possible in one position only

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30 - 5 Nm
mer
atio
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31 - Protective plate
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❑ Renew
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❑ Observe tightening sequence ⇒ page 71

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33 - Engine support
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2.2 Removing and installing toothed belt

⇒ “2.2.1 Removing and installing toothed belt, tensioning roller A”,
page 135
⇒ “2.2.2 Removing and installing toothed belt, tensioning roller B”,
page 142
2. Toothed belt drive 133


equipment required
AG. Volkswagen AG d
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♦ Pin - 3359- f inform

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♦ Angle driver - T10264- for tensioning roller

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♦ Locking tool - T10265-

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♦ Angle driver, 8 mm - T10409- for tensioning roller B
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Not illustrated:
Differences between versions of tensioning roller
AG. Volkswagen AG d
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Note by
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2 versions of tensioning roller
aut are fitted. They are not interchange‐
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able. When performing adjusting
ss measures, check first to see c
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which tensioning roller is installed.

un
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Observe different directions of rotation during tensioning
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Features of tensioning roller A:
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♦ Locking tool - T10265- required for installation.
hole
spec
es, in part or in w
♦ Check tensioning roller is seated correctly in timing belt guard
t to the co
⇒ page 139
♦ Tension toothed belt by turning tensioning roller eccentric
satelettronica
rrectness of i
»clockwise«
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Features of tensioning roller B:

♦ Locking tool not required.
nform
ercia
♦ Tensioning roller is not seated in toothed belt guard.

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a
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♦ Tension toothed belt by rotating tensioning roller eccentric
on in
»anticlockwise«
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2.2.1 Removing and installing toothed belt,

cted agen
Prote AG.
tensioning roller A
Removing
Note
The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending on
the engine temperature.
Caution
Risk of irreparable damage if direction of rotation is reversed

on previously used toothed belt.
♦ Before removing toothed belt, mark direction of rotation
with chalk or felt tipped pen for installation purposes.

– Remove bolts -3- and remove coolant reservoir -2-.

– Release and unplug electrical connector from coolant expan‐
sion tank -2-.
– Place coolant expansion tank -2- to one side.
lkswage es n
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– Open plug-in connectors -A- and -B- for fuel lines and ir se pull off
d ran
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fuel lines. Disconnect plug-in connector ⇒ Rep.ugr. th 20 ; Dis‐
o
or
connecting plug-in connector . ss
a ac
ce
le

un
pt
an
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erm
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– If installed, remove supplementary fuel pump - V393- or fuel
ility
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pump 2 - V277- ⇒ Rep. gr. 20 ; Fuel pump; Removing and
wit
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installing fuel pump .
h re
satelettronica
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spec
t to the co
rrectne
– Unplug connector from pressure differential sender - G505-
-2-.
ss
– Remove bolts -1-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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by
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Prote AG.
– Unplug connector of radiator outlet coolant temperature send‐

er - G83- , open clips -arrows- and remove toothed belt guard.
– Remove poly V-belt ⇒ page 60 .
– Remove vibration damper ⇒ Item 29 (page 133) .

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– Remove lower and middle toothed belt
ss guards -arrows- and
unscrew securing nuts of coolant pipe -1-.
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– Turn engine to TDC and lock crankshaft sprocket in position

with crankshaft stop - T10050- . To do this, push crankshaft
nf
ercia
stop into sprocket teeth from face side of sprocket. Depending
orm
on the production version, either the toothed segment or the
m
atio
m
arrow on the camshaft toothed belt pulley must be at »12

o
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c
o'clock«.
or
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The markings on the crankshaft pulley -2- and the crankshaft stop
C py
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- T10050- -1- must align. At the same time, the pin of the crank‐
ht
pyri by
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shaft stop - T10050- must engage in the drilling in the sealing
c by lksw
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flange.
Prote AG.
– Mark direction of rotation of toothed belt.
– Loosen securing bolts -1- of camshaft pulley.
– Loosen securing bolt of coolant pipe -1- and then securing

bolts of sprocket for high-pressure pump -2-.
– Loosen belt tensioner securing nut -1-.

– Turn eccentric of tensioning roller anti-clockwise -arrow- using

angle driver - T10264- until tensioning roller can be locked with
locking tool - T10265- .
– Now turn tensioning roller eccentric clockwise -arrow- onto

stop and tighten securing nut -1- hand-tight.
– Remove toothed belt first from idler pulley and then from re‐
maining toothed pulleys.
Installing
AG. Volkswagen AG d
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lksw not
satelettronica
Note d by Vo gu
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♦ The tootheds abelt may only be adjusted on cold engines, as theor ac
ut
indicator position on the tensioning element varies depending
s
ce
e
on the engine temperature.

nl
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♦ If the tensioning roller is to be renewed, the engine bracket

erm
ab
must be removed ⇒ page 71 .

ility
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• Tensioning roller must be locked with locking tool - T10265-

hole
and secured to right stop.

spec
es, in part or in w
t to the co
• Crankshaft is locked using crankshaft stop - T10050- .

rrectness of i
Note
l purpos
If necessary, turn camshaft hub with counterhold - T10172- and

adapters - T10172/4- until camshaft hub can be secured in posi‐
tion. To do this, hand-tighten at least one securing bolt -1-.
nform
mercia
at
om
io
– Lock the camshaft hub with locking pin - 3359- . To do this,

n
c
in t
or
insert locking pin through outer free elongated hole into hole
his
ate
in cylinder head.
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– Loosen hand-tightened bolts again.

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Note pyri by
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Prote AG.
If necessary, turn hub of high-pressure pump at bolt heads with
screwdriver until hub can be secured in position.

Positioning hub of high-pressure pump
AG. Volkswagen AG d
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olksw not
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– Lock high-pressure pump hub with diesel injection pump lock‐
s
satelettronica
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ing pin - 3359- . To do this, push locking pin into adjustment

un
pt
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hole outside toothed belt pulley.

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erm
ab
– Turn camshaft pulley and toothed belt pulley of high-pressure
ility
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pump in their elongated holes clockwise to stop.

wit
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– Fit toothed belt to crankshaft pulley, tensioning roller, cam‐
ole,
spec
shaft pulley, toothed belt pulley of coolant pump and toothed
belt pulley of high-pressure pump.

t to the co
– Finally, place toothed belt onto idler pulley.

– Undo the fastening nuts of the tensioning roller and pull out
rrectne
locking tool - T10265- .

ss o
cial p
Note
inform
mer
Ensure that tensioning roller seats correctly in rear toothed belt

atio
om
guard -arrow-.
n
c
i
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te
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Seat of tensioning roller in cylinder head

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Prote AG.

– Screw eccentric of tensioning roller clockwise carefully using

angled screwdriver - T10264- . Indicator -2- must be roughly
past the centre of the gap in the base plate (corrects itself dur‐
ing pretensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten fastening nuts
of tensioning roller as follows: 20 Nm and then turn another
45°.
– Fit counterhold - T10172- as shown. Press counter-hold tool -

T10172- in direction of arrow and keep camshaft pulley in
pretensioning position.
– In this position, first tighten bolts -1- of camshaft sprocket and
of high-pressure pump sprocket finger-tight and then tighten
to 20 Nm.
– Remove locking pins - 3359- and crankshaft stop - T10050- .
satelettronica
– Turn crankshaft at least 2 rotations in engine direction of ro‐
tation and set again to TDC no. 1 cylinder.
– Place crankshaft stop - T10050- on crankshaft toothed belt
pulley again.
– Now turn crankshaft in engine direction of rotation until crank‐

shaft stop pin -arrow- engages in sealing flange whilst turning.
AG. Volkswagen AG d
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co Vo
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cted
Rep. gr.15 - Cylinder head, valve gear
agen
Prote AG.
Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. A mi‐
nor deviation -arrow-, though, does not influence engine opera‐
tion.
– Ensure that:
♦ Camshaft hub can be locked with locking pin - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
If camshaft hub cannot be locked:
– Pull crankshaft stop - T10050- back until pin unblocks hole.
– Turn crankshaft out slightly past TDC by turning it counter to
direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
satelettronica
– After locking, loosen securing nuts of crankshaft pulley.
If pin of crankshaft stop - T10050- is standing on left next to hole:
– Turn crankshaft in direction of engine rotation until pin of

crankshaft stop engages in sealing flange whilst turning.
– Tighten bolts of camshaft sprocket finger-tight initially and then
to 20 Nm.
If pin of crankshaft stop - T10050- is standing on right next to hole:
– Turn crankshaft slightly opposite direction of engine rotation.
n AG. Volkswagen A
– Then turn crankshaft oinlksdirection
wage of engine rotation
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shaft stop pin engages
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– Tighten boltsuthof
o camshaft sprocket finger-tight initially and then
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Continuation
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– Remove locking pin - 3359- and crankshaft stop - T10050- .

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spec
– Repeat measurement.
es, in part or in w
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– If camshaft hub can be secured in position, tighten securing

bolts as follows:
rrectness of i
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♦ Camshaft sprocket: 45° further. Counterhold with counterhold

- T10172- and adapters - T10172/4- .
– Install middle and lower toothed belt guards.
– Install vibration damper/belt pulley. Tighten to specified torque
10 Nm and then turn a further 90°.
– Install upper toothed belt guard.
♦ Do not interchange fuel supply and return lines (return line is
blue or with blue markings and supply line is white).
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liner; Removing and installing
wheel housing liner .
tion .
satelettronica
2.2.2 Removing and installing toothed belt,
tensioning roller B olkswagen AG
en AG. V ag does
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The toothed belt may only be adjusted on cold engines, as the

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indicator position on the tensioning element varies depending on

rm
ab
pe
the engine temperature.

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Caution
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Risk of irreparable damage if direction of rotation is reversed

on previously used toothed belt.
rrectness of i
♦ Before removing toothed belt, mark direction of rotation

with chalk or felt tipped pen for installation purposes.
l purpos
nform
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m

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Prote AG.

– Remove bolts -3- and remove coolant reservoir -2-.

– Release and unplug electrical connector from coolant expan‐
sion tank -2-.
– Place coolant expansion tank -2- to one side.
WARNING
Danger of scalding from very hot fuel.

♦ In extreme cases, the temperature of the fuel and the fuel
lines can reach 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- risk of scalding.
– Open plug-in connectors -A- and -B- for fuel lines and pull off
fuel lines. Disconnect plug-in connector ⇒ Rep. gr. 20 ; Dis‐
connecting plug-in connector n A.G. Volkswagen AG do
satelettronica
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– Remove fuel filter ed
b⇒
y V Rep. gr. 20 ; Fuel filter; Removing
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– If installed,
ss remove supplementary fuel pump - V393- or fuel c
pump 2 - V277- ⇒ Rep. gr. 20 ; Fuel pump; Removing and
ce
e
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erm
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ility
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– Unplug connector from pressure differential sender - G505-

t to the co
-2-.
– Remove bolts -1-.
rrectness of i

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nform
mercia
at
om
ion
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ate
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AG. V agen AG
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– Remove toothed belt guard, db
opening
y Vo
clips -arrows- to do so.ot gua
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ris tee
– Remove front right wheelutho housing liner ⇒ General body re‐ or
pairs, exterior; Rep.ssgr. 66 ; Wheel housing liner; Removing
a ac
ce
le
un
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– Remove vibration damper ⇒ Item 29 (page 133) .
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spec
t to the co
– Remove centre and lower toothed belt guards -arrows-.
rrectness o
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– Turn engine to TDC and lock crankshaft sprocket in position
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with crankshaft stop - T10050- .
agen
Prote AG.
– To do so, push crankshaft stop from face side of sprocket onto

teeth of crankshaft toothed belt pulley-2-. Depending on the
production version, either the toothed segment or the arrow
on the camshaft toothed belt pulley must be at »12 o'clock«.
Note
The markings on the crankshaft pulley -2- and the crankshaft stop
- T10050- -1- must align.
– Pin of crankshaft stop - T10050- must engage in bore

-arrow- in sealing flange.
– Mark direction of rotation of toothed belt.

– Loosen securing bolts -1- of camshaft pulley.
AG. Volkswagen AG d
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– Loosen securing bolts of sprocket of high-pressure pump -2-.
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– Loosen belt tensioner securing nut -1-.

o
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– Use angle driver - T10409- to rotate eccentric -2- of tensioning
te
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roller clockwise -arrow- until tensioning roller is relieved of

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– Hand-tighten securing bolt -1-.
Co
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– Remove toothed belt first from idler pulley and then from re‐
rig ht
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maining toothed pulleys. by c lksw
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Installing
Note
♦ The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending
on the engine temperature.
♦ If the tensioning roller is to be renewed, the engine bracket
must be removed ⇒ page 71 .
♦ 2 versions of tensioning roller are fitted. They are not inter‐
changeable. When performing adjusting measures, check first
to see which tensioning roller is installed.
• Crankshaft is locked using crankshaft stop - T10050- .
Note
Turn camshaft hub with counterhold - T10172- and adapters -

T10172/4- until camshaft hub can be secured in position. To do
this, hand-tighten at least one securing bolt -1-.


insert locking pin through outer free elongated hole into hole
in cylinder head.
– Loosen hand-tightened bolts again.
Note
Turn hub of high-pressure pump at bolt heads with screwdriver

until hub can be secured in position.
Positioning hub of high-pressure pump
AG. Volkswagen AG d
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push locking pin into adjustment hole outside toothed belt pul‐
nform
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ley.
m
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com
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– Turn camshaft sprocket and toothed belt sprocket of high-

on in
pressure pump in their elongated holes clockwise to stop.

r
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– Fit toothed belt to crankshaft pulley, tensioning roller, cam‐

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shaft pulley, toothed belt pulley of coolant pump and toothed

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belt pulley of high-pressure pump.

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– Finally, place toothed belt onto idler pulley.
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– Loosen tensioning roller securing nut.
co lksw
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Prote AG.
– Carefully turn eccentric -2- of tensioning roller anticlockwise

-arrow- using angle driver, 8 mm - T10409- . Indicator -4- must
be slightly past centre of gap in base plate -3- (rectifies itself
during pretensioning).
Ensure that securing nut -1- does not turn as well.

Markings on tensioning element and tensioning roller -arrow- are

now almost aligned.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
– Fit counterhold - T10172- as shown. Press counterhold -

T10172- in direction of arrow and keep camshaft sprocket in
pretensioned position.
– In this position initially hand-tighten securing bolts of camshaft
sprocket and high-pressure pump sprocket.
– Tighten securing bolts to 20 Nm.
– Remove locking pins - 3359- and crankshaft stop - T10050- .
satelettronica
– Place crankshaft stop - T10050- on crankshaft toothed belt
pulley again.
– Turn crankshaft in direction of engine rotation until crankshaft

stop pin -arrow- engages in sealing flange whilst turning.
AG. Volkswagen AG d
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Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very difficult to find . Volkswagen AG
the securing position of the high-pressure pump hub again. Alkmi‐ swa
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– Check whether: s
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♦ Camshaft hub can be locked with locking pin - 3359- .
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♦ Tensioning roller indicator is centred or maximum 5 mm to
ility
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If camshaft hub cannot be locked:
hole
spec
– Pull crankshaft stop - T10050- back until pin clears hole.
es, in part or in w
t to the co
– Turn crankshaft out slightly past TDC by turning it counter to
direction of engine rotation.
rrectness of i
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
satelettronica
l purpos
– After locking camshaft sprocket, loosen securing nuts.
nform
ercia
If pin of crankshaft stop - T10050- is standing on left next to hole:

m
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– Turn crankshaft in direction of engine rotation until pin of
n
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crankshaft stop engages in sealing flange whilst turning.

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– Hand-tighten camshaft sprocket securing bolts initially.

p
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– Tighten camshaft toothed belt sprocket securing bolts to 20
en
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If pin of crankshaft stop - T10050- is standing on right next to hole: yri
p by
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– Turn crankshaft slightly opposite direction of engine rotation.
agen
Prote AG.
– Turn crankshaft in engine direction of rotation until crankshaft

stop pin arrow engages in sealing flange whilst turning.
– Hand-tighten camshaft sprocket securing bolts initially.
– Tighten camshaft toothed belt sprocket securing bolts to 20
Nm.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Repeat measurement.
If camshaft hub can be secured in position, tighten securing bolts
as follows:

♦ Counterhold with counterhold - T10172- and adapters -

T10172/4- .
♦ Then tighten securing bolts to 20 Nm.
♦ Camshaft sprocket: 45° further.
– Install middle and lower toothed belt guards.
– Install vibration damper/belt pulley.
– Install upper toothed belt guard.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line white).
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
satelettronica
tion .
Specified torque: wage

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Component ised b ran
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Specified torque
or
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Tensioningau pulley
t or
ac 20 Nm + 45°
ss
Camshaft sprocket 20 Nm + 45°
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High-pressure pump pulley 20 Nm

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Vibration damper/belt pulley 10 Nm + 90°

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⇒ “3.1 Assembly overview - valve gear”, pagey V150 olk not
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⇒ “3.2 Measuring axial play of camshaft”,horis
page 152 eo
aut ra
⇒ “3.3 Measuring radial play of camshaft”,
ss page 153 c
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nl
pt
⇒ “3.4 Removing and installing camshaft”, page 153
du
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⇒ “3.5 Removing and installing camshaft oil seal”, page 160
ab
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⇒ “3.6 Checking hydraulic compensation elements”, page 165
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⇒ “3.7 Removing and installing valve stem seals”, page 165
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3.1 Assembly overview - valve gear
t to the co
Caution
rrectness of i
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Avoid damage to valves and piston crowns after working on

valve gear.
nform
ercia
♦ Because hydraulic compensation elements have to settle,
satelettronica
engine must not be started for approx. 30 minutes after
m
at
installing camshafts.
om
ion
c
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♦ Turn the crankshaft carefully at least 2 rotations to ensure

o
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te
that none of the valves make contact when the starter is

a
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operated.
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t.
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Note
co Vo
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Prote AG.
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the
cracks are small and no more than 0.5 mm wide.

1 - Valve
❑ Do not rework; only
grinding-in is permissi‐
ble
❑ Mark installation posi‐
tion for re-installation.
❑ Checking ⇒ page 173
❑ Valve dimensions
⇒ page 172
❑ Checking valve guides
⇒ page 172
2 - Cylinder head
3 - Valve stem seal
❑ Renewing with cylinder
head installed n AG. Volkswagen AG do
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⇒ page 165 . byV
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❑ Renewing with cylinder ir se tee
ho
head removed aut or
ac
⇒ page 168 . ss
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4 - Valve springs
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5 - Valve spring plate
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6 - Valve cotters
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7 - Cap
spec
es, in part or in w
❑ Renew
t to the co
❑ Removing: With retain‐
ing frame installed,
pierce one side of cap
rrectness of i
with an awl and pry out.
l purpos
❑ Installing: Drive in with‐

out sealant using an ap‐
propriate thrust piece.
nform
ercia
❑ Drive in depth 1 to 2 mm
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8 - Oil seal
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9 - Exhaust camshaft
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❑ Measuring axial clearance ⇒ page 152 .
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❑ Measuring radial clearance ⇒ page 153 p by
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10 - Bolt Prote AG.

11 - Ladder frame
❑ With integrated camshaft bearings.
12 - Inlet camshaft
❑ Measuring axial clearance ⇒ page 152 .
❑ Measuring radial clearance ⇒ page 153
13 - Roller rocker fingers
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
3. Valve gear 151

14 - Retaining clip
❑ For hydraulic compensation element.
15 - Hydraulic compensation element
❑ Mark installation position for re-installation.
❑ Lubricate contact surfaces before installing. AG. Volkswagen AG d
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Retaining frame - specified torques and installation
uthor
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– Tighten bolts in 2 stages in the sequence
s shown:
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• The retaining frame must make
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contact with the cylinder head over
h re
the entire contact surface.
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spec
es, in part or in w
2) -1 … 24- 10 Nm
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
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tion in
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te o
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3.2 Measuring axial play of camshaft
s
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♦ Universal dial gauge holder - VW 387-
C py
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Prote AG.
Procedure
– Remove retaining frame ⇒ page 153 .

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– Fasten dial gauge - VAS 6079- to cylinder shead
s a with universal ac
dial gauge bracket - VW 387- as shown in the illustration.
ce
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– Press camshaft against dial gauge by hand.
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– Set dial gauge to “0”.
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– Press camshaft away from dial gauge and read off value:
h re
ole,
spec
Axial clearance of inlet and outlet camshafts:
t to the co
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm.
rrectnes
3.3 Measuring radial play of camshaft
s o
cial p
f inform
mer
atio
♦ Plastigage
om
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Procedure
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– Remove roller rocker finger.

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satelettronica
fo
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– Remove bearing cap and clean crankshaft journal.
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t.
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– Place a length of Plastigage corresponding to the width of the
. C rig
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bearing on the journal to be measured or into the bearings. py by
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• The Plastigage must lie in the middle of the bearing. Prote AG.
– Fit retaining frame and tighten to 10 Nm ⇒ page 152 without

twisting crankshafts.
– Remove retaining frame.
– Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.035 to 0.085 mm.
3.4 Removing and installing camshaft
3. Valve gear 153


equipment required
AG. Volkswagen AG d
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♦ Diesel injection pump locking pin - 3359-

nform
ercia

m
at
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ion
♦ Puller - T10052-
c
in t
or
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♦ Camshaft fitting tool - T40094-

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♦ Camshaft clamping tool - T40095-

f
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♦ Camshaft fitting tool - T40096- t. Cop py
rig
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♦ Torque wrench - V.A.G 1331/-
co Vo
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Prote AG.

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♦ Silicone adhesive sealant - D 176501 A1-
mer
atio
m
Removing
o
n
c
i
or
n
thi
te
sd
iva
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pr
cum
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fo
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ng
t.
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op
– If installed, remove supplementary fuel pump - V393- or fuel
satelettronica
C py
t. rig
pump 2 - V277- ⇒ Rep. gr. 20 ; Fuel pump; Removing and gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 133 .
– Remove cylinder head cover ⇒ page 124 .
– Unscrew securing bolts -1- of camshaft pulley.
– Remove camshaft sprocket from hub.
– Counterhold hub with counter-hold tool - T10051- and release

hub securing bolt -1-.
– Unscrew hub securing bolt approx. 2 turns.
3. Valve gear 155

– Position puller - T10052- and align with hub holes.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with 30 mm spanner.
– Remove hub from taper of camshaft.

– Remove vacuum pump ⇒ page 129 .
– Unscrew securing bolts of retaining frame in sequence

-24 … 1-.
– Remove retaining frame.
– Carefully remove camshafts.
Installing
satelettronica
Note
. Volkswagen AG
gen AG does
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Seal parting surface y Vbetween retaining frame and cylinder
olk not
gu head
using silicone adhesive
rised b
sealant - D 176 501 A1- . ara
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Caution
nl
pt
du
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The camshafts may be installed only with the camshaft fitting

erm
ab
ility
tool - T40094- as described below. The axial bearings in the

ot p
retaining frame will otherwise be damaged beyond repair and

wit
, is n
h re
the cylinder head will have to be renewed.

hole
spec
es, in part or in w
t to the co
– Remove sealant residues on cylinder head and retaining

frame, e.g. using a plastic rotary brush.
rrectness of i
Caution
l purpos
Make sure that no sealant residue gets into the cylinder head
or the bearings.
nf
ercia
orm
m
atio
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– Sealing surfaces must be free of oil and grease.

or c
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te
sd
– Oil running surfaces of camshafts.

iva
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rp
cu
If not already done, set up camshaft fitting tool - T40094- as fol‐

o
m
f
en
ng
lows:
t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

– Remove supports -T40094/3-, -T40094/4- and -T40094/5-

from base plate. Threaded connection is accessible from be‐
low.
Note
If the supports of the camshaft fitting tool - T40094- are not yet
marked, mark the removed supports, e.g. with number stamps,
so they can be fitted in the original positions later.
– Install supports -T40094/9- and -T40094/10- instead at vacant

outer positions.
– Place support -T40094/2- at position “A” and support
-T40094/1- at position “F”.
– First insert inlet camshaft as shown. Ensure that indentation
-arrow- for cylinder head bolt faces »outwards«.
satelettronica
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– Position 0.50 mm feeler gauge and push support -T40094/8-
ce
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nl
pt
into inlet camshaft groove.
du
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itte
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ab
ility
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wit
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spec
es, in part or in w
t to the co
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– Insert exhaust camshaft and lock via groove -arrow- with

nf
ercia
-cover T40094/11-.
orm
m
– Position clamping tool - T40096/1- on exhaust camshaft

atio
om
sprockets.
n in
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Caution
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Ensure that the clamping jaw marked with an arrow is seated
yi Co
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on the wider gear.
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Prote AG.
3. Valve gear 157

– Tighten clamping tool - T40096/1- using knurled wheel so that

faces of gear teeth are in alignment. Use a 13 mm open-ended
spanner.
– Slide exhaust camshaft towards inlet camshaft until teeth en‐
gage.
– Place retaining frame on camshafts.
• All camshaft bearings must be seated on the camshafts.
. Volkswagen AG
gen AG does
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– Position camshaft fitting tool - T40095- y V as shown, thereby fix‐
olk not
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ing camshafts in position in retaining
rised b
frame. ara
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– Remove cover - T40094/11- au.t ra
ss c
ce
le
– Pull support - T40094/8- out of inlet camshaft groove.

un
pt
an
d
itte
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rm
ab
pe
ility
ot
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2 mm).
l purpos
– Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto

clean sealing surfaces of cylinder head as illustrated.
nform
ercia
Caution
m
a
com
tion in
Risk of soiling camshaft bearings due to surplus sealant and

r
te o
thi
risk of sealing oil supply bores.

s
iva
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♦ Do not apply sealant beads thicker than specified.

fo
en
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t.
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♦ When applying sealing near oil supply holes -arrow- for
Co
Cop py
retaining frame, make sure that they are not plugged by ht. rig
rig ht
excess sealant.
py by
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Prote AG.

Sealant bead for retaining frame

– Remove camshafts from camshaft fitting tool - T40095- to‐
gether with retaining frame and camshaft fitting tool - T40094- .
– Carefully insert camshafts and retaining frame into cylinder AG. Volkswagen AG d
head. agen oes
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– First tighten securing bolts of retaining frame finger-tight in
satelettronica
s
sequence -1 … 24-.
s o
cial p
f
• The retaining frame should make contact with the cylinder
inform
head over the complete surface.
mer
atio
m
– Tighten retaining frame bolts to final torque in sequence

o
n
c
-1 … 24-. Specified torque: 10 Nm
i
or
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te
sd
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– Remove camshaft fitting tool - T40095- and clamping tool -

iv
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c
T40096/1- .
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t.
yi
– Renew camshaft seal ⇒ page 160 .
Co
Cop py
ht. rig
– Using a suitable drift, drive new cap ⇒ Item 7 (page 151) into rig ht
py by
cylinder head until flush.
co Vo
by lksw
cted agen
Prote AG.
Perform further installation in reverse order, paying attention to
the following:
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
– Fit hub on camshaft.
3. Valve gear 159

– Tighten hub securing bolt -1- to 100 Nm. Use counter-hold tool
- T10051- to do this.
– Push camshaft pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
satelettronica
– Insert securing bolts -1- by hand without play to camshaft pul‐
ley.
– Lock hub with locking pin - 3359- .
– Install toothed belt and adjust the valve timing ⇒ page 133 .
– Install vacuum pump ⇒ page 129 .
– Install fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
– If installed as original equipment, install supplementary fuel
pump - V393- or fuel pump 2 - V277- ⇒ Rep. gr. 20ol;ksFuel
wagen AG
pump; Removing and installing fuel pumpsw.agen AG. V does
k not
Vol gu
d by ara
e
3.5 Removing and installing camshaft oil ris nte
utho eo
ra
seal
a c
ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
A new seal -B- will be gradually introduced. This new seal does
, is n
h re
not provide a closed surface between the camshaft and cylinder

hole
spec
head but has a fillet. A different procedure has to be followed here

es, in part or in w
⇒ page 162 .
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
3.5.1 Vehicles with »old« seal
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
♦ Fitting tool - V.A.G 10-203-
ce
e
nl
pt
du
an
itte
♦ Seal puller - 3240-

y li
erm
ab
ility

ot p
wit
, is n

h re
hole
spec
♦ Bolt M12 x 1.5 x 75

es, in part or in w
t to the co
Removing
– Remove toothed belt from camshaft and high-pressure pump
rrectness of i
⇒ page 133 .
– Remove camshaft sprocket and hub ⇒ page 153 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 161

– Insert thrust piece -3240/1- into camshaft.

– Unscrew inner part of oil seal extractor -3240- 2 turns (approx.
3 mm) from outer part, and lock it in place using knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
G. Volkswagen AG d
until oil seal is pulled out. lkswagen A oes
n o ot g
yV ua
Installing ris
edb ran
tee
tho or
au
satelettronica
ac
ss
Note
ce
le
un
pt
an
d
itte
Do not be additionally oil or grease the oil seal sealing lip. y li

rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaft as

es, in part or in w
shown in illustration.
t to the co
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
– Press seal in as far as stop using thrust piece from fitting tool
fo
en
g
10-203 and bolt M12×1.5×75.

n
t.
yi Co
Cop py
– Install camshaft sprocket and hub ⇒ page 153 .
t. rig
gh ht
pyri by
Vo
o
– Install toothed belt and adjust the valve timing ⇒ page 133 . by c lksw
cted agen
Prote AG.
3.5.2 Vehicles with »new« seal


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Fitting tool - V.A.G 10-203-

♦ Seal puller - T10443-
nform
ercia

m
at
om
ion

c
in t
or
his
te
♦ Bolt M12 x 1.5 x 75

a
do
priv
cum
or
Removing
f
en
ng
t.
yi Co
– Removed toothed belt from camshaft and high-pressure pump Cop py
t. rig
⇒ page 133 . opyri
gh by
Vo
ht
c
– Remove camshaft sprocket and hub ⇒ page 153 .
by lksw
cted agen
Prote AG.
Caution
If turned too far anti-clockwise, the inner thrust plate becomes

detached from the pressure screw. In this case, the thrust plate
must be pushed back onto the pressure screw.
– Turn pressure screw of oil seal extractor anti-clockwise »very

carefully« until slight resistance can be felt.
3. Valve gear 163

Note
. Volkswagen AG
gen AG does
swa
The clamping sleeves of the oil seal y V extractor are fitted with grub ot gu
olk n
screws. However, only one ofristhese
ed
b
grub screws -arrow- effects ara
nte
clamping, the other is fixed.utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Fit oil seal extractor as shown and screw in grub screw -A- to
clamp it in place.
t to the co
– Screw pressure screw -B- in until oil ring has been pulled out.
rrectne
Installing
ss o
Note
cial p
f i
satelettronica
nform
mer
Do not be additionally oil or grease the oil seal sealing lip.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaft as
r
fo
en
ng
shown in illustration. The lettering on the oil seal faces out‐

t.
yi Co
wards. Cop py
t. rig
gh ht
yri
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
p by
o Vo
by c lksw
cted agen
Prote AG.
– Press seal in as far as stop using thrust piece from fitting tool
10-203 and bolt M12×1.5×75.
– Install camshaft sprocket and hub ⇒ page 153 .
– Install toothed belt and adjust the valve timing ⇒ page 133 .

3.6 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal.

♦ Feeler gauge
Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes; per‐
form road test if necessary.
Note
satelettronica
If the irregular valve noises stop but recur repeatedly during short
journeys, the oil retention valve must be renewed. The oil reten‐
tion valve is located in the oil filter bracket
⇒ Item 10 (page 191) .
Volkswa
– If the hydraulic compensation elements
agen are still noisy,
AG. gen AG
find
does out
ksw
which is the defective compensation
by Vol
element as follows: not
gu
a d ran
ise
– Remove cylinder head
tho cover ⇒ page 124 .
r tee
or
u ac
sa
– Turn crankshaft bys the bolt for the toothed belt wheel until cam
ce
e
of supporting element to be tested is facing upwards.

nl
pt
du
an
itte
y li
– Press roller rocker finger downwards -arrow- to check clear‐

erm
ab
ance between cam and roller rocker finger.

ility
ot p
wit
– If a 0.20 mm feeler gauge can be inserted between cam and

, is n
h re
roller rocker finger, renew hydraulic compensation element.

hole
spec
Concluding measures
es, in part or in w
t to the co

rrectness of i
l purpos
nform
ercia
3.7 Removing and installing valve stem

m
at
om
io
seals
n
c
in t
or
his
te
⇒ “3.7.2 Renewing valve stem seals with cylinder head removed”,

a
do
riv
page 168
p
cum
for
en
ng
⇒ “3.7.1 Renewing valve stem seals with cylinder head installed”,

t.
yi Co
op
page 165 C py
t. rig
gh ht
yri by
3.7.1 Renewing valve stem seals with cylinder
cop Vo
by lksw
cted agen
head installed
Prote AG.
3. Valve gear 165

♦ Valve stem seal puller - 3364-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
♦ Valve stem seal fitting tool - 3365- auth ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
satelettronica
spec
t to the co
rrectne
♦ Removal and installation device for valve cotters - VAS 5161-
ss
with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1-
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Bolt M6×30 (qty. 2)

Procedure
– Remove all glow plugs ⇒ page 395 .
– Remove camshafts ⇒ page 153 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Set piston of respective cylinder to “bottom dead centre”.

– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
– Screw sealing pins -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into relevant glow
plug thread.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
– Insert drift -VAS 5161/3- into guide plate and tuse
ho a plastic
r eo
hammer to knock loose the firmly seated valve
ss au
cotters. ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw toothed piece -VAS 5161/6- with hooking fork -
l purpos
VAS 5161/5- into guide plate.

– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
nf
ercia
VAS 5161/8- .
rm
m
atio
m
– Connect adapter to compressed air supply using a commer‐

o
n in
c
cially available union and apply pressure continuously.

or
thi
te
sd
a
• Minimum pressure: 6 bar.

iv
o
r
rp
cu
o
– Attach pressure fork -VAS 5161/2- to toothed piece and press

f
en
ng
t.
assembly cartridge down.
yi Co
Cop py
t. rig
– At the same time, turn knurled screw of assembly cartridge
gh ht
yri by
clockwise until tips engage in valve cotters.
op Vo
by c lksw
cted agen
Prote AG.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with knurled spacer ring.
– Remove valve spring and valve spring plate.
3. Valve gear 167

– Pull off valve stem seal using valve stem seal puller - 3364- .
– Lightly oil sealing lip of valve stem oil seal and valve stem.
– Carefully push valve stem oil seal on valve stem -A-.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
satelettronica
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device
agen
AG.-Volkswagen AG d
oes
VAS 5161/18- . Vo lksw not
g y ua
db ran
• Larger diameter of valve cotters faces upwards.
or
ise tee
th or
au
– Insert valve spring and valve spring plate.
ss
ac
ce
e
nl
– Press assembly cartridge onto valve cotter insertion device pt

du
an
from above and pick up valve cotters.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert assembly cartridge into guide plate -VAS 5161/23-

again.
– Press pressure fork downwards and pull knurled screw up‐
rrectness of i
wards, turning it clockwise and anticlockwise. This inserts the

l purpos
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
nf
ercia
screw.
orm
m
– Repeat procedure on each valve.

atio
om
n in
c
Installing
or
thi
te
sd
a
Assembly is carried out in reverse sequence; note the following:

iv
o
r
rp
cu
o
– Ensure that all roller rocker fingers contact valve stem ends
f
en
ng
t.
yi
correctly and are clipped into relevant hydraulic compensation
Co
op py
elements. t. C rig
gh ht
pyri by
– Install camshafts ⇒ page 153 .
o Vo
by c lksw
cted agen
Prote AG.
– Install glow plugs ⇒ page 395 .
3.7.2 Renewing valve stem seals with cylinder head removed


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Valve stem seal puller - 3364-

es, in part or in w
t to the co
♦ Valve stem seal fitting tool - 3365-

♦ Removal and installation device for valve cotters - VAS 5161-
rrectness of i
with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1-

l purpos
♦ Engine and gearbox support - VAS 6095-

♦ Cylinder head tensioning device - VAS 6419-
nform
ercia
♦ Bolt M6×30 (qty. 2)

m
a
com
ti
Procedure
on in
r
te o
thi
– Remove camshafts ⇒ page 153 .

s
iva
do
r
– Mark allocation of roller rocker fingers and hydraulic compen‐

rp
cum
fo
sation elements for reinstallation.

en
ng
t.
yi Co
op
– Remove roller rocker fingers together with hydraulic compen‐
C py
ht. rig
sation elements and place down on a clean surface.
rig ht
py by
co Vo
by lksw
– Insert cylinder head tensioning device - VAS 6419- into engine
cted agen
Prote AG.
and gearbox support - VAS 6095- .
3. Valve gear 169

– Tension cylinder head on cylinder head tensioning device as

shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
satelettronica
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Screw toothed piece -VAS 5161/6- with hooking fork -

t to the co
VAS 5161/5- into guide plate.

– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
rrectne
– Attach pressure fork -VAS 5161/2- to toothed piece and press

assembly cartridge down.
ss o
cial p
– At the same time, turn knurled screw of assembly cartridge

inform
clockwise until tips engage in valve cotters.

mer
atio
m
– Move knurled screw back and forth to press apart valve cotters
o
n
c
and capture them in assembly cartridge.

i
or
n thi
te
sd
a
– Release pressure fork.

iv
o
pr
cum
r
fo
– Remove assembly cartridge with knurled spacer ring.

en
ng
t.
yi Co
op
– Remove valve spring and valve spring plate. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Pull off valve stem seal using valve stem seal puller - 3364- .
– Lightly oil sealing lip of valve stem oil seal and valve stem.
– Carefully push valve stem oil seal on valve stem -A-.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
If the valve cotters have been removed from the assembly car‐
an
d
itte
tridge, they must first be inserted into the valve insertion device -
y li
rm
ab
VAS 5161/18- .
pe
ility
ot
• Larger diameter of valve cotters faces upwards.

wit
, is n
h re
hole
– Insert valve spring and valve spring plate.

spec
es, in part or in w
– Press assembly cartridge onto valve cotter insertion device

t to the co
from above and pick up valve cotters.

rrectness of i
l purpos
– Insert assembly cartridge into guide plate -VAS 5161/23-

nform
ercia
again.
m
a
com
ti
– Press pressure fork downwards and pull knurled screw up‐

on in
wards, turning it clockwise and anticlockwise. This inserts the

r
te o
thi
valve cotters.
s
iva
do
r
rp
– Reduce pressure on pressure fork whilst pulling on knurled

um
fo
en
g
screw.
n
t.
yi Co
op py
– Repeat procedure on each valve.
t. C rig
gh ht
pyri by
Vo
o
Installing by c lksw
cted agen
Prote AG.
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensation
elements.
– Install camshafts ⇒ page 153 .
3. Valve gear 171

4 Inlet and exhaustksw valves

A G. Volkswagen AG d
agen oes
not
Vol y gu
db ara
⇒ “4.1 Valve dimensions”, opage
ris
e 172 nte
h eo
ut ra
⇒ “4.2 Reworking valve
ss seats”, page 172
a c
ce
le
⇒ “4.3 Checking valve guides”, page 172

un
pt
an
d
itte
y li
⇒ “4.4 Checking valves”, page 173
rm
ab
pe
ility
4.1 Valve dimensions
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
rrectness of i
l purpos
Dimension Inlet valve Outlet valve

∅a mm 28.10 26.00
nform
ercia
∅b mm 5.975 5.965
m
satelettronica
com
t
c mm 99.30 99.10
ion in
r
α ∠° 45 45
te o
thi
s
iva
do
r
rp
cum
4.2 Reworking valve seats
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
Valve seats must not be reworked due to the very narrow toler‐
ances.
4.3 Checking valve guides

♦ Universal dial gauge holder - VW 387-

Procedure
Note
♦ If the valve is to be renewed as part of a repair, use a new

valve for the measurement.
♦ Due to differing stem diameters, only use an intake valve in
satelettronica
intake guide and an exhaust valve in exhaust guide.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Insert valve into valve guide.
olkswagen AG
ag en AG. V
• The end of the valveVostem
lksw must be flush with the
does
guide.
not
y gu
db ara
– Determine rock.
or
ise nte
h eo
ut ra
• Wear limit:ss a1.0 mm. c
ce
le
– If the wear limit is exceeded, repeat the measurement with

un
pt
an
d
new valves.
itte
y li
rm
ab
– Renew cylinder head if wear limit is still exceeded.

pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Valve guides cannot be exchanged.

rrectness of i
4.4 Checking valves

l purpos
– Check for scoring on valve stems and valve seat surfaces.

– Exchange valve if significant scoring can be seen.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Inlet and exhaust valves 173

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 174
⇒ “1.2 Removing and installing sump”, page 178
⇒ “1.3 Removing and installing oil pump”, page 183
⇒ “1.4 Removing and installing oil level and oil temperature send‐
er”, page 185
⇒ “1.5 Engine oil:”, page 186 AG. Volkswagen AG d
agen oes
ksw
1.1 Assembly overview - sump/oil pump
ol not
byV gu
ara
ed
ris nte
o
⇒ “1.1.1 Assembly
aut overview - sump/oil pump, engine codes
h eo
ra
CFFA, CFFB,s CFGB, CFGC, CFFD, CLLA, CLJA”, page 174
s c
ce
e
nl
pt
⇒ “1.1.2 Assembly overview - sump/oil pump, engine codes
du
an
itte
CFHB, CFHC, CFHF, CFJA, CFJB, CLCA”, page 177
y li
erm
ab
ility
satelettronica
1.1.1 Assembly overview - sump/oil pump, engine codes CFFA, CFFB, CFGB,
ot p
wit
, is n
CFGC, CFFD, CLLA, CLJA

h re
hole
spec
es, in part or in w
Note t to the co
♦ Metal shavings or a large quantity of small metal particles found during engine repair could indicate that the
rrectness of i
crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work
must be carried out following the repair: Carefully clean oil channels and renew oil spray jets, engine oil
l purpos
cooler and oil filter.

♦ Oil capacities, oil specifications, viscosity grades ⇒ Maintenance tables .
nf
ercia
orm
♦ Oil spray jet and pressure relief valve ⇒ page 178 .

m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
174 Rep. gr.17 - Lubrication

CC 2010 ➤ , Eos 2006 agen➤ , Golf 2009A➤
AG. Volkswagen G d, Golf Plus 2009 ➤ , Passat 2011 ...
oes
ksw not
4-cylinder
by V common rail engine (2.0 l, EA189
ol
gu
a
ed ran
oris tee
1 - Seal au
th or
ac
ss
❑ Permanently attached
ce
le
un
to drain plug
pt
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2 - Oil drain plug, 30 Nm
erm
ab
ility
ot p
3 - Sump
wit
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h re
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⇒ page 178
spec
4 - 9 Nm
t to the co
5 - Suction line
❑ Clean strainer if soiled
rrectne
6 - O-ring
ss
❑ Renew
o
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f in
7 - Oil pump
form
mer
atio
m
⇒ page 183
o
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that the two dowel

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sleeves for centring oil
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pump on balancer shaft
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module are fitted. t. Cop py
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8 - Input shaft yri
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❑ For oil pump. cted agen
Prote AG.
9 - Retaining ring
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
10 - Spur gear
❑ for balancer shaft
❑ Renew
12 - Thrust washer
❑ For intermediate gear wheel.
❑ Renew
❑ Fitting position ⇒ page 176
❑ To install intermediate gear wheel, secure to balancer shaft module with grease.
13 - Intermediate gear
❑ Renew
❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
wear.
❑ Installation position: Part number must be visible.
❑ Make sure thrust washer is seated correctly ⇒ page 176 .
14 - 90 Nm + 90°
❑ With washer
❑ Renew
15 - Hub
❑ Renew
1. Sump, oil pump 175

16 - Crankshaft sprocket
17 - Balancer shaft module
❑ Removing ⇒ page 201
❑ Reinstalling previously run balancer shaft module ⇒ page 205 .
❑ Installing new balancer shaft module ⇒ page 202 .
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block
are fitted.
18 - M7 = 13 Nm + turn 90° further; M8: 20 Nm + turn 90° further
❑ Renew
❑ Note tightening sequence: installing new balancer shaftwmodule
agen ⇒olpage
AG. V kswage202
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oes
balancer shaft module ⇒ page 205 . y Volks not
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19 - Dowel sleeves oris nte
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th or
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20 - 9 Nm ss
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21 - Oil extraction pipe
an
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22 - 9 Nm
erm
ab
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23 - Seal
wit
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satelettronica
❑ Renew
ole,
spec
24 - Oil level and oil temperature sender - G266-
t to the co
25 - 9 Nm
rrectne
❑ Self-locking
❑ Renew
ss o
26 - Bolt
cial p
f inform
❑ Renew
mer
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Thrust washer installation position

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Caution Cop py
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Risk of thrust washer slipping behind intermediate gear wheel.
co Vo
by lksw
cted agen
Prote AG.
♦ When installing intermediate gear wheel, make sure that
thrust washer -A- does not slip out of balancer shaft mod‐
ule indentations -arrows- and subsequently become jam‐
med. If necessary, fix in place with grease on balancer
shaft module.

1.1.2 Assembly overview - sump/oil pump, engine codes CFHB, CFHC, CFHF,
CFJA, CFJB, CLCA
1 - 15 Nm
2 - Sealing flange
❑ With seal
❑ Must seat on dowel
sleeves.
⇒ page 87
❑ Install with silicone seal‐
ant - D 176 404 A2- .
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
satelettronica
❑ Renewing crankshaft oil
seal, belt pulley end
⇒ page 91 .
3 - Toothed belt for oil pump
❑ Check for damage and
wear.
❑ Renew if necessary.
Note
♦ Belts which have been in use agen

AG. Volkswagen AG d
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longer can sag. olksw not
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♦ This is not a fault and does not ris nte
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necessarily mean belt needs re‐ aut ra
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placing. s ce
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un
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4 - 10 Nm
y li
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5 - Oil dipstick
ot
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❑ The oil level must not be above the max. mark!

h re
hole
❑ Markings ⇒ page 186 .

spec
es, in part or in w
6 - Guide tube
t to the co
7 - Clip
rrectness of i
8 - Dowel sleeves
❑ Renew
l purpos
9 - O-ring
nform
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❑ Renew
m
10 - 10 Nm
com
tion in
11 - Oil pump with pressed-on toothed belt pulley

r
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❑ With 12 bar pressure relief valve

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❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
fo
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t.
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If toothed belt or oil pump have to be removed: Cop py
♦ Check oil pump for free movement
t. rig
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♦ It should be possible to turn belt pulley easily with 1 finger.
by c lksw
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♦ Renew if tight/sticking.
12 - Suction line
13 - Baffle plate
14 - 15 Nm
15 - Bolt
16 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D176404A2- .
17 - 15 Nm
18 - Seal
❑ Renew
19 - Oil drain plug, 30 Nm AG. Volkswagen AG d
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❑ Renew not
satelettronica
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20 - 10 Nm hor eo
aut ra
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21 - Oil level and oil temperature sender - G266- ss
ce
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nl
❑ Black 3-pin connector
pt
du
an
itte
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ab
ility
ot p
22 - Seal
wit
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❑ Renew
h re
hole
spec
23 - Oil level/oil temperature sender wiring harness
es, in part or in w
t to the co
24 - 27 Nm
❑ Insert without sealant.
25 - Oil spray jet rrectness of i
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Oil spray jet and pressure relief valve

nf
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1- Bolt with pressure relief valve, 27 Nm

m
atio
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2- Oil spray jet (for cooling of pistons)

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Note
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When renewing the oil spray jet, ensure correct allocation to pis‐ C py
t. rig
ton ⇒ ETKA (Electronic Parts Catalogue) . gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.2 Removing and installing sump


♦ T-bar and socket, 10 mm - 3185-
♦ Multi-point bit - T10058-

AG. Volkswagen AG d
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nl
pt
du
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satelettronica
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ab
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spec
es, in part or in w
t to the co
♦ Hand drill with plastic brush
♦ Sealant ⇒ Electronic Parts Catalogue
rrectness of i
♦ Safety glasses
l purpos
Removing
nf
ercia
– Drain engine oil ⇒ Maintenance ; Booklet .
orm
m
atio
– Remove air hose; loosen hose clip -2- and raise retaining clip
om
-1- for this.
n in
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t.
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Cop py
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rig ht
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co Vo
by lksw
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– Free coolant hose -3-.
– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove right air pipe.
– Unscrew bolt -arrow- and push coolant circulation pump 2 -
satelettronica
V178- to the side.
AG. Volkswagen AG d
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olksw not
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ce
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nl
pt
du
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ab
ility
ot p
– Unscrew bolt -arrow- on left air pipe.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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– Disconnect electrical connector -arrow- on oil level and oil

o
his
te
temperature sender - G266- .

a
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priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Open fasteners -arrows- and remove noise insulation -1- for

sump.
– In vehicles with an auxiliary heater, remove bracket for coolant
lines from oil sump on right.
AG. Volkswagen AG d
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– Unscrew bolts -arrows- of sump to gearbox connection.
ce
le
un
pt
an
d
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– Slacken bolts -1 … 20- in diagonal sequence and remove.
y li
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ab
pe
ility
– Release sump carefully from adhesive.
ot
wit
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Installing
h re
hole
spec
es, in part or in w
Caution
t to the co
satelettronica
Danger of soiling lubrication system and bearings.
rrectness of i
♦ Cover open parts of engine.
l purpos
nform
ercia
WARNING
m
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com
ti
Risk of eye injury.
on in
r
te o
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♦ Wear safety goggles.
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
– Remove sealant residues from sump and cylinder block using Cop py
t. rig
rotating plastic brush or similar. pyri
gh by
Vo
ht
co
– Clean sealing surfaces; they must be oil- and grease-free.
by lksw
cted agen
Prote AG.

Note
Observe use-by-date of sealant.

2 mm).
Caution
Danger of blocking lubrication system with excess sealant.

♦ Do not apply sealant bead thicker than specified.
– Apply bead of sealant onto clean sealing surface of sump as

illustrated. wage es n
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db ara
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• Thickness of sealantthbead:
or
2…3 mm. eo
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nl
pt
satelettronica
Note
du
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ab
♦ Take particular care when applying the sealant bead near the
ility
ot p
rear sealing flange -arrows-.
wit
, is n
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♦ The sump must be installed within 5 minutes after sealant is
hole
spec
applied.
es, in part or in w
– Position oil sump and tighten bolts . t to the co

rrectness of i
Note
l purpos
♦ When installing the sump with the engine removed from the
vehicle, ensure that the sump is flush with the cylinder block
nf
ercia
at the flywheel end.

rm
m
atio
m
♦ Allow sealant to dry for approx. 30 minutes after installing

o
n in
c
sump. Only then fill with engine oil.

or
thi
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Sump - specified torque and tightening sequence
Note
Renew bolts for oil sump.
– Tighten bolts in 3 stages:

1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
15 Nm
– Install coolant circulation pump 2 - V178- .
– Install air pipes ⇒ page 253 .
– Installing intake hoses with screw-type clips ⇒ page 254 .
satelettronica
tion .
– Replenish engine oil, and check oil level ⇒ Maintenance ;
Booklet .
1.3 Removing and installing oil pump

⇒ “1.3.1 Removing and installing oil pump, engine codes CFFA,
CFFB, CFGB, CFGC, CFFD, CLLA, CLJA”, page 183
wage es n
⇒ “1.3.2 Removing and installing oil pump, engine codesyCFHB,
Vol
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ua
CFHC, CFHF, CFJA, CFJB, CLCA”, page 184 ris
ed b ran
tee
tho or
1.3.1 Removing and installing oilss apump,
u
en‐ ac
gine codes CFFA, CFFB, CFGB, CFGC,
ce
e
nl
pt
du
an
CFFD, CLLA, CLJA
itte
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ab
ility
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♦ Circlip pliers (commercially available)

h re
hole
♦ M3 bolt spec
es, in part or in w
t to the co
Removing
rrectness of i
– Unscrew bolts -arrows- and pull suction line off oil pump.
l purpos
nf
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orm
m
atio
om
n in
or c
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sd
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t.
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Cop py
t. rig
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pyri by
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co lksw
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cted agen
Prote AG.

– Remove circlip -1- with circlip pliers.

– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
– Unscrew bolts -3, 4, 5- and remove oil pump.
Caution
Bolt on intermediate gear wheel must not be loosened.
Installing
⇒ “4.1 Assembly overview - balancer shaft module”,
page 199 .
Install in reverse order of removal.
Note
♦ Renew O-ring.
satelettronica
♦ Renew circlip if damaged or overstretched. agen
AG. Volkswagen AG d
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♦ The retaining ring must seat in the base of the edgroove.
b ara
nte
ris
ho eo
aut ra
ss c
– Insert dowel sleeves if oil pump has no dowel sleeves
ce
le
un
-arrows-.
pt
an
d
itte
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– Insert dowel sleeves if balancer shaft module has no dowel
erm
ab
sleeves for centring oil pump.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
1.3.2 Removing and installing oil pump, en‐

cial p
f inform
gine codes CFHB, CFHC, CFHF, CFJA,

mer
atio
CFJB, CLCA
om
n
c
i
or
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Removing
te
sd
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p
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fo
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t.
– When oil pump is to be renewed, unscrew bolts -4- and remove
yi Co
op
oil intake pipe -3-.
C py
ht. rig
rig ht
py by
– Unscrew bolts -arrows- and remove baffle -2-. co Vo
by lksw
cted agen
Prote AG.
– Detach oil pump -1- from toothed belt and remove pump.

Installing agen
AG. Volkswagen AG d
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• Specified torques ⇒ page 177 . d by V gu
ara
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Install in reverse order of removal. autho eo
ra
ss c
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nl
pt
du
Note
an
itte
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erm
ab
Renew O-ring.
ility
ot p
wit
, is n
h re
– Insert new dowel sleeves when oil pump has no dowel sleeves
hole
spec
-arrows- for centring oil pump.
es, in part or in w
t to the co
– Check oil pump for ease of movement, turn toothed belt pulley
with one finger for this.
rrectness of i
Note
l purpos
Renew oil pump if sluggish.
nform
mercia
– Check toothed belt for oil pump.
at
om
satelettronica
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
♦ Renew toothed belt if damaged.
en
ng
t.
yi Co
op
♦ The toothed belt can sag after long use, this is not a fault.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Fit oil pump with toothed belt pulley into toothed belt and tight‐ Prote
cted AG.
agen
en along with baffle.
– Replenish engine oil and check oil level ⇒ page 186 .
1.4 Removing and installing oil level and oil

temperature sender
Removing
– Drain engine oil ⇒ Maintenance ; Booklet .
– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
Installing
⇒ “4.1 Assembly overview - balancer shaft module”,
page 199 .
Note
Renew seal -2- and self-locking bolts -1-.
– Replenish engine oil, and check oil level ⇒ Maintenance ;

Booklet .

1.5 Engine oil:
AG. Volkswagen AG d
Note agen oes
olksw not
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The oil level must remain below the max. mark - danger ofthdam‐
oris nte
eo
age to catalytic converter! Markings ⇒ page 186 . s au ra
c
s
ce
e
nl
pt
Drain engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or
du
an
itte
extract; renew oil filter and replenish engine oil .
y li
erm
ab
ility
Engine oil specifications ⇒ Maintenance ; Booklet ; Service ta‐
ot p
wit
bles .
, is n
h re
⇒ “1.5.1 Oil capacities”, page 186 hole
spec
es, in part or in w
⇒ “1.5.2 Checking engine oil level”, page 186
t to the co
1.5.1 Oil capacities
rrectness of i
With oil filter change: 4.3 l
l purpos
Without oil filter change: 4.0 l
satelettronica
1.5.2 Checking engine oil level
nform
mercia
at
om
ion
c
Note
in t
or
his
ate
do
riv
The oil level may be in area -d- due to the infiltration of fuel in the
p
cum
or
engine oil as a result of unfavourable driving conditions after fill‐

f
en
g
ing. This is a perfectly normal and self-regulating characteristic.

n
t.
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op
It is not necessary to adjust the engine oil level. C py
ht. rig
rig ht
py by
co Vo
1 - Min. mark
by lksw
cted agen
Prote AG.
2 - Max. mark
a - Oil level in min. mark area: replenish engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Oil level in max. mark area: do not replenish engine oil.
d - The oil level may be in this area as a result of particular driving
conditions.

2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 187
⇒ “2.2 Removing and installing engine oil cooler”, page 188
2.1 Assembly overview - engine oil cooler

olkswagen AG
en AG. V
1 - Cap olks
wag does
not
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❑ 25 Nmised b ara
nte
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2 - O-ring au
t ra
c
ss
❑ Renew
ce
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un
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an
d
3 - O-ring
itte
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erm
ab
❑ Renew
ility
ot p
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4 - O-ring
is n
h re
ole,
❑ Renew
spec
5 - Oil filter element
t to the co
satelettronica
❑ Observe notes
⇒ page 174
rrectne
⇒ Maintenance ; Book‐
let 808
ss o
cial p
f
6 - Engine oil cooler
inform
❑ Observe notes
mer
atio
⇒ page 174
om
n
c
❑ Connection diagram for

i
or
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coolant hoses
te
sd
va
⇒ page 208
i
o
pr
cum
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fo

en
ng
t.
⇒ “2.2 Removing and in‐
yi Co
op
stalling engine oil cool‐
C py
t. rig
gh
er”, page 188
ht
pyri by
Vo
co lksw
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❑ Renew coolant after re‐ Prote
cted AG.
agen
placing
7 - 11 Nm
8 - Seals
❑ Renew
9 - Bolt
❑ Renew
❑ With integrated oil retention valve.
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 188
11 - Seals
❑ Renew
2. Engine oil cooler 187

Oil filter bracket - specified torques and sequence
Note
Renew bolts for oil filter bracket.
– First tighten upper left and lower right bolts.

1) -Arrows- In diagonal sequence to 14 Nm
2) -Arrows- turn 90° further diagonally
2.2 Removing and installing engine oil cool‐

er
♦ Release lever - 80 - 200-
satelettronica
AG. Volkswagen AG d
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♦ Used oil collection and extraction
rised b
unit - V.A.G 1782- ara
nte
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aut ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
nf
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orm
m
atio
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n in
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sd
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Spring-type clip pliers - VAS 6362-
AG. Volkswagen AG d
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nl
pt
du
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ab
ility
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Removing
wit
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hole
spec
– Remove air intake cowling ⇒ page 240 .
es, in part or in w
t to the co
– Remove oil filter element ⇒ Maintenance ; Booklet .
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

- G31- / intake air temperature sender - G42- and remove right
air pipe.
2. Engine oil cooler 189

– Pull out oil dipstick slightly, unscrew bolt -1-.

– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
AG. Volkswagen AG d
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spec
t to the co
– Place drip tray for workshop hoist - VAS 6208- under point of
satelettronica
separation.
rrectne
– Remove coolant hoses. To do this, loosen hose clips -1-.
ss
– Place used oil collection and extraction unit - V.A.G 1782- un‐
o
cial p
f i
der engine.
nform
mer
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
atio
m
gine oil cooler.

o
n
c
i
or
n thi
Installing
te
sd
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• Specified torques
p
cum
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fo
⇒ “2.1 Assembly overview - engine oil cooler”, page 187 .

en
ng
t.
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op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note
Prote AG.
♦ Renew gaskets, seals and O-rings.

♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure hose connections with hose clips meeting production
standard ⇒ Electronic Parts Catalogue .
– Install dipstick guide tube ⇒ page 199 .

– Install charge air pipe ⇒ page 253 .
– Install air filter housing ⇒ page 293 .
– Install cowling ⇒ page 240 .
– Install oil filter element, replenish engine oil and check oil level
⇒ Maintenance ; Booklet .
– Replenish coolant in cooling system, change coolant if engine
oil cooler has been renewed ⇒ page 209 .

3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter housing, oil pressure switch”,
page 191
⇒ “3.2 Removing and installing oil pressure switch”, page 192
AG. Volkswagen AG d
⇒ “3.3 Checking oil pressure”, page 192 agen oes
olksw not
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⇒ “3.4 Checking oil pressure and oil pressure switch”,orise nte
page 193 aut
h eo
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⇒ “3.5 Removing and installing oil filter housing”, page 195
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nl
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3.1 Assembly overview - oil filter housing, oil pressure switch
itte
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1 - Cap
h re
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❑ 25 Nm
spec
es, in part or in w
2 - O-ring
t to the co
❑ Renew
3 - O-ring
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satelettronica
❑ Renew
l purpos
4 - O-ring
❑ Renew
nform
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5 - Oil filter element
at
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❑ Observe notes
n
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⇒ page 174
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⇒ Maintenance ; Book‐
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let 808
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❑ Observe notes
co Vo
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cted
⇒ page 174
agen
Prote AG.

coolant hoses
⇒ page 208
⇒ “2.2 Removing and in‐
stalling engine oil cool‐
er”, page 188
❑ Renew coolant after re‐
placing
7 - 11 Nm
8 - Seals
❑ Renew
9 - Bolt
❑ Renew
❑ With integrated oil retention valve.
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 188
11 - Seals
❑ Renew
3. Oil filter, oil pressure switch 191

Oil filter bracket - specified torques and sequence
Note
Renew bolts for oil filter bracket.
– First tighten upper left and lower right bolts.

1) -Arrows- In diagonal sequence to 14 Nm
2) -Arrows- turn 90° further diagonally
3.2 Removing and installing oil pressure

switch
Removing
satelettronica
– Press release buttons and remove hose -1- for venting crank‐
case.
– Move clear vacuum hoses -arrows-.
– Remove air pipe from air filter housing; release hose clip -3-
for this.
– Unscrew bolt -2-, swing air pipe with inlet connection to rear
and pull off from turbocharger.
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– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
itte
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– Separate electrical connector -arrow-.

ility
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– Remove oil pressure switch - F1- .

h re
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spec
Installing
t to the co
⇒ “1.1 Assembly overview - cylinder head”, page 113 .
rrectness
Note
o
cial p
f inform
Fit gasket.
mer
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n
c
– Install vacuum line to exhaust gas recirculation cooler

i
or
n thi
⇒ page 381 .
te
sd
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– Install intake pipe ⇒ page 241 .

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3.3 Checking oil pressure
C py
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♦ Oil pressure tester - V.A.G 1342-
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Procedure
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• Oil level OK.
wit
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• Engine oil temperature approx. 80°C.
hole
spec
es, in part or in w
t to the co
Note
satelettronica
The specified test values relate to an oil temperature of approx.
rrectness of i
80°C. The oil pressure will be lower at higher oil temperatures. If
the specifications are not reached, check whether the oil temper‐
l purpos
ature for this test is too high (> 120°C).
nf
ercia
o
– Remove oil pressure switch - F1- ⇒ page 192 .
rm
m
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– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
o
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c
sure switch - F1- .

or
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– Screw an old oil pressure switch into hole on oil pressure tester
iv
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- V.A.G 1342- to seal hole.
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– Start engine.
Co
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• Minimum oil pressure at idling speed: 0.6 bar. rig ht
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• Minimum oil pressure at 2,000 rpm: 1.0 bar. cted agen
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3.4 Checking oil pressure and oil pressure

switch
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Adapter set - V.A.G 1594C-
satelettronica
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Procedure
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• Oil level OK.
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• Engine oil temperature approx. 80°C. h re

ole,
– Remove oil pressure switch - F1- ⇒ page 192 .

spec
t to the co
– If needed, screw adapter - V.A.G 1342/19- into bore for oil

pressure switch.
rrectness o
cial p
f inform
mer
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Cop py
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by c lksw
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Prote AG.

– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch or adapter - V.A.G 1342/19- .
– Screw oil pressure switch - F1- -item 2- into hole in oil pressure
tester.
– Connect brown line -1- of oil pressure tester to earth (–).
– Connect voltage tester - V.A.G 1527B- with auxiliary cables
from auxiliary measuring set - V.A.G 1594C- to oil pressure
switch - F1- and battery positive (+).
• LED should not light up.
Note
If LED lights up already, renew oil pressure switch - F1- .
– Start engine.
Note
satelettronica
Observe the oil pressure tester and LED while starting, since the
switching point of the oil pressure switch may already be excee‐
ded when starting.
• LED should light up at 0.3 to 0.6 bar.

– If LED does not light up, renew oil pressure switch - F1-
⇒ page 192 .
3.5 Removing and installing oil filter housing

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♦ Used oil collection and extraction unit - V.A.G 1782-

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4-cylinder common
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♦ Drip tray for workshop
ss hoist - VAS 6208-
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Cop py
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Removing
– Remove air intake cowling ⇒ page 240 .
– Remove oil filter element ⇒ Maintenance ; Booklet .


air pipe.
– Pull out oil dipstick slightly, unscrew bolt -1-.
satelettronica
to side.
AG. Volkswagen AG d
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

– Place drip tray for workshop hoist - VAS 6208- under point of
separation.
– Remove coolant hoses. To do this, loosen hose clips -1-.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
⇒ “2.1 Assembly overview - engine oil cooler”, page 187 .
Install in reverse order of removal
Note
AG. Volkswagen AG d
♦ Renew gaskets, seals and O-rings. lksw
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♦ Hose unions and air intake pipes andisehoses must be free of
d b ara
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oil and grease before installation.uthor eo
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satelettronica
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♦ Secure hose connections with hoses clips in such a way that
ce
e
factory standard is restored ⇒ Electronic parts catalogue

nl
pt
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– Install dipstick guide tube ⇒ page 199 .
ility
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– Install charge air pipe ⇒ page 253 .
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install cowling ⇒ page 240 .
rrectness of i
– Install oil filter element, replenish engine oil and check oil level
⇒ Maintenance ; Booklet .
l purpos
– Replenish coolant in cooling system, change coolant if engine

oil cooler has been renewed ⇒ page 209 .
nform
mercia
at
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c
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do
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Cop py
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4 Balancer shaft module
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⇒ “4.1 Assembly overview - balancer shaft module”, page 199
pe
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⇒ “4.2 Removing and installing balance shaft module”,
wit
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page 201
hole
spec
4.1 Assembly overview - balancer shaft module
es, in part or in w
t to the co
1 - Seal
rrectness of i
❑ Permanently attached
to drain plug
l purpos
2 - Oil drain plug, 30 Nm
nform
ercia
3 - Sump
m
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com
tio
⇒ page 178
n in
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4 - 9 Nm
s
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5 - Suction line
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Co
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6 - O-ring
gh ht
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❑ Renew
lksw
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Prote AG.
7 - Oil pump
⇒ page 183
that the two dowel
sleeves for centring oil
pump on balancer shaft
module are fitted.
8 - Input shaft
❑ For oil pump.
9 - Retaining ring
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
10 - Spur gear
❑ for balancer shaft
❑ Renew
12 - Thrust washer
❑ Renew
❑ To install intermediate gear wheel, secure to balancer shaft module with grease.
13 - Intermediate gear
❑ Renew
❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
wear.
❑ Installation position: Part number must be visible.
❑ Make sure thrust washer is seated correctly ⇒ page 201 .
4. Balancer shaft module 199

Volkswagen AG
14 - 90 Nm + 90° agen
AG. does
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❑ With washered by V gu
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❑ Renew uthor eo
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15 - Hub s
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❑ Renew
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16 - Crankshaft sprocket
wit
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17 - Balancer shaft module
hole
spec
❑ Removing ⇒ page 201
es, in part or in w
t to the co
❑ Reinstalling previously run balancer shaft module ⇒ page 205 .
❑ Installing new balancer shaft module ⇒ page 202 .
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block
rrectness of i
are fitted.
l purpos
18 - M7 = 13 Nm + turn 90° further; M8: 20 Nm + turn 90° further

❑ Renew
nform
ercia
❑ Note tightening sequence: installing new balancer shaft module ⇒ page 202 , reinstalling previously run
m
at
balancer shaft module ⇒ page 205 .
om
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satelettronica
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19 - Dowel sleeves
o
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20 - 9 Nm
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21 - Oil extraction pipe

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22 - 9 Nm t. C rig
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23 - Seal
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❑ Renew
AG.
24 - Oil level and oil temperature sender - G266-

25 - 9 Nm
❑ Self-locking
❑ Renew
26 - Bolt
❑ Renew
Sump - specified torque and tightening sequence
Note
Renew bolts for oil sump.

1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
15 Nm

Thrust washer installation position
Caution

♦ When installing intermediate gear wheel, make sure that
thrust washer -A- does not slip out of balancer shaft mod‐
ule indentations -arrows- and subsequently become jam‐
med. If necessary, fix in place with grease on balancer
shaft module.
4.2 Removing and installing balance shaft

module
⇒ “4.2.1 Removing balancer shaft module”, page 201
⇒ “4.2.2 Installing a new balancer shaft module”, page 202
⇒ “4.2.3 Installing a previously used balancer shaft module
again”, page 205
satelettronica
AG. Volkswagen AG d
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4.2.1 Removing balancer shaft module
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Special tools and workshop equipment required aut
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Procedure
inform
mer
– Pull out oil dipstick.

atio
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– Remove vibration damper ⇒ page 62 .

n
c
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or
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Caution
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Risk of destruction due to toothed belt jumping.
Co
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♦ Only turn crankshaft in engine direction of rotation. rig ht
py by
co Vo
by lksw
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Prote AG.
– Turn crankshaft at bolt for toothed belt pulley until crankshaft

is at “TDC”.

– Lock crankshaft in position with crankshaft stop - T10050- .

• The markings on the toothed belt pulley -2- and the crankshaft
stop -1- must align -arrow-. When doing this, the pin of the
crankshaft stop must engage in the drilling of sealing flange.
Note
The crankshaft stop can be pushed onto the toothed belt sprocket
only from the face side.

– Unscrew bolts in sequence -8 … 1- or -6 … 1- and remove
balance shaft module together with oil pump.
Balancer shaft module with 8 threaded connection points
satelettronica
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Balancer shaft module with 6 threaded
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Note
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♦ Installing a new balancer shaft module ⇒ page 202 .

ot
wit
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♦ Reinstalling the previous balance shaft module ⇒ page 205 .

hole
spec
es, in part or in w
t to the co
rrectness of i
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mercia
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tion in
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4.2.2 Installing a new balancer shaft module

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Cop py
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♦ Locking device - T10255-
AG. Volkswagen AG d
Procedure olksw
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• Specified torques rised ara
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⇒ “4.1 Assembly overview - balancerutshaft module”,
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page 199 . ss a c
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• Crankshaft locked in position with crankshaft stop - T10050- .

un
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Note
ot
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♦ The spur gear drive of the balancer shaft module must be in‐
hole
spec
stalled with correct tooth backlash.
es, in part or in w
t to the co
♦ A coating of correct thickness is applied to the new intermedi‐
ate gear wheel to set the correct backlash. The coating is
applied in part around the teeth.
rrectness of i
♦ The coating is quickly worn away, which sets the correct back‐
l purpos
lash.
♦ A new balance shaft module must always be installed with a
nform
ercia
new intermediate gear wheel with coating.

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♦ Renew bolts that are tightened with specified tightening angle.
com
tion in
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Caution
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Cop py
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♦ To fit balance shaft module, do not loosen intermediate
gh ht
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gear wheel bolt more than specified. Thrust washer in‐
op Vo
by c lksw
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stallation position ⇒ page 176
agen
Prote AG.
– Loosen bolt -1- for intermediate gear wheel approx. 45°.

– Insert dowel sleeves if no dowel sleeves for centring balance
shaft module are fitted on cylinder block.
– Place balancer shaft module on cylinder block.
• Coating on intermediate gear wheel must not be damaged.

Tightening sequence - balancer shaft module with 8 bolted con‐

nection points
– Tighten bolts of balancer shaft module as follows:
1) -1 … 8- Hand-tighten in sequence
2) -1 … 8- Initially tighten in sequence to 6 Nm
3) -1 … 4- Tighten to 20 Nm
4) -5- Tighten to 13 Nm
8) -1 … 8- Turn bolts 90° further in sequence us‐
ing a fixed wrench AG. Volkswagen AG d
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Tightening sequence - balancer shaft module with 6 bolted con‐ ss c
satelettronica
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4) -5- and -6- Tighten to 13 Nm
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– Lock balance shaft with locking tool - T10255- ; if necessary,

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turn balance shaft.

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• Locking tool pin must engage in groove in balancer shaft when
t. C rig
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doing this. p by
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– Carefully fit balance shaft gear wheel onto balance shaft; push
intermediate gear wheel slightly to side for this.
• Coating on intermediate gear wheel must not be damaged.
AG. Volkswagen
• If possible, threaded holes of balance shaft
wage should be located
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centrally in elongated holes of balance
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If the elongated holes in the balance shaft gear wheel cannot be

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aligned to the threaded holes, turn the balance shaft gear wheel
erm
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a suitable number of teeth and fit it again.
ot p
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– Tighten bolts -arrows- for balance shaft gear wheel.
spec
– Remove locking tool - T10255- .
t to the co
rrectne
Note
The following 3 procedures must be performed simultaneously
ss
satelettronica
o
(2nd mechanic required).
cial p
f inform
mer
– Press intermediate gear wheel -3- forcefully (with assistance
atio
m
of a wooden rod if necessary) in -direction of arrow- into spur

o
n
c
gear teeth -2- and balance shaft gear wheel -1-.
i
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– Turn balance shaft gear wheel slightly anticlockwise whilst do‐

iv
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ing this.
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– Tighten bolt for intermediate gear wheel.
Co
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– Remove crankshaft stop - T10050- .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
No backlash may be perceptible after installing intermediate gear

wheel. This can be checked by hand using light force.
Continue installation in reverse order of removal:

– Install vibration damper ⇒ page 62 .
4.2.3 Installing a previously used balancer

shaft module again
♦ Locking device - T10255-

Procedure
Caution
If the intermediate gear wheel bolt was loosened, the drive gear
wheel on the crankshaft was renewed or the crankshaft was
removed, a new intermediate gear wheel with coating must be
installed and the hub ⇒ Item 15 (page 200) with
⇒ Item 14 (page 175) and thrust washers must be renewed.
Otherwise, the tooth backlash will be incorrect. Procedure
when installing ⇒ page 202 .
Note
♦ Proceed as follows if the previously used balance shaft mod‐

ule is being reinstalled and neither the spur gear on the crank‐
shaft nor the crankshaft have been renewed. The intermediate
gear wheel must also not have been loosened.
♦ Renew bolts that are tightened with specified tightening wangle.
agen
AG. Volkswagen AG d
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– Lock balance shaft with locking tool - T10255- ris; if necessary,
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turn balance shaft. tho eo
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• Locking tool pin must engage in groove in balancer shaft when
ce
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un
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doing this.
an
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– Insert dowel sleeves if no dowel sleeves for centring balance
erm
ab
ility
shaft module are fitted on cylinder block.
ot p
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– Place balancer shaft module on cylinder block.
h re
ole,
spec
• The intermediate gear wheel must mesh in the crankshaft spur
gear when the balance shaft is locked.
t to the co
• The intermediate gear wheel must have a slight tooth back‐
lash.
rrectne
ss o
cial p
f inform
mer
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Tightening sequence - balancer shaft module with 8 bolted con‐

thi
te
sd
a
nection points
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3) -1 … 4- Tighten to 20 Nm Prote AG.
ing a fixed wrench

AG. Volkswagen AG d
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th
au ra
s c
Tightening sequence - balancer shaft module with 6 bolted con‐ s
ce
e
nection points
nl
pt
du
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ility
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4) -5- and -6- Tighten to 13 Nm
ing a fixed wrench
rrectness of i
– Remove crankshaft stop - T10050- .
l purpos
Continue installation in reverse order of removal:
nf
ercia
orm
m
atio
– Install vibration damper ⇒ page 62 .
om
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or c
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Prote AG.

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Coolant hose connection diagram”, page 208
⇒ “1.2 Draining and adding coolant”, page 209
⇒ “1.3 Checking cooling system for leaks”, page 213
1.1 Coolant hose connection diagram
1 - Coolant expansion tank

❑ With cap
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 213 .
2 - Cylinder head and cylinder
block
satelettronica
❑ Renew coolant after re‐
placing
3 - Exhaust gas recirculation
cooler n AG. Volkswagen AG do
lkswage es n
❑ Checking exhaust gas byV
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ua
recirculation cooler for ir se
d ran
tee
leaks ⇒ page 385 autho
or
ac
ss
4 - Auxiliary heater
ce
le
un
pt
❑ With recirculation pump
an
d
itte
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- V55- .
rm
ab
pe
ility
❑ Not necessarily instal‐
ot
wit
led
, is n
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hole
5 - Heat exchanger for heater
spec
es, in part or in w
6 - Gear oil cooler

t to the co
❑ Only for dual clutch
gearbox. rrectness of i
7 - Thermostat
l purpos
❑ Only for dual clutch

gearbox.
nform
ercia
8 - Coolant circulation pump 2

- V178-
m
a
com
tion in
r
te o
Caution
thi
s
iva
do
After fitting a new coolant

r
rp
cum
circuit pump, it is essen‐

fo
en
ng
tial to bleed the cooling

t.
yi Co
op
system using the VAS
C py
t. rig
gh
6096 ⇒ page 209 . If this
ht
pyri by
Vo
is not done, air inclusions
co lksw
by
cted agen
can cause consequential Prote AG.
damage to the exhaust
gas recirculation cooler
as a result of overheat‐
ing.
9 - Radiator for engine coolant

❑ Renew coolant after replacing
208 Rep. gr.19 - Cooling

10 - Thermostat
❑ Not necessarily installed
11 - Engine oil cooler
12 - 4/2-way valve with thermostat
13 - Coolant pump
1.2 Draining and adding coolant

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
satelettronica
ise nte
or eo
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aut ra
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nl
pt
du
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erm
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ility
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wit
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
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cted agen
Prote AG.
♦ Refractometer - T10007AA-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
1. Cooling system/coolant 209

1.2.1 Draining agen

AG. Volkswagen AG d
oes
olksw not
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ara
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is nte
WARNING hor eo
aut ra
ss c
Hot steam may escape when expansion tank is opened. Cover
ce
e
nl
pt
cap with cloth and open carefully.
du
an
itte
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erm
ab
ility
ot p
– Open filler cap on coolant expansion tank.
wit
, is n
h re
hole
spec
es, in part or in w
sulation .
t to the co
– Pull coolant hoses -1- off coolant circulation pump 2 - V178-
-2-.
rrectness of i
l purpos
nform
mercia
at
satelettronica
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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op py
– Remove air intake hose. To do this, loosen hose clips -1- and . C rig
ht ht
-2-.
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Pull out retaining clip -arrow- for lower coolant hose and pull
coolant hose off plug-in connector of radiator.

– In addition to draining coolant from engine, pull the coolant

hose off the engine oil cooler -arrow-.
Note
Please observe disposal instructions!
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

1.2.2 Replenishing
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
satelettronica
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
swa
gen AG
. Volkswagen AG
does
must be used to determine the current anti-freeze
by
Vol value.
k not
gu
ara
ed
♦ The scale -1- of the refractometer is calibrated for the coolant
ris nte
tho eo
additives G12++ and G12evo. au ra
c
ss
ce
e
♦ The scale -2- of the refractometer is calibrated for the coolant

nl
pt
du
additive G13.
an
itte
y li
erm
ab
♦ If it is not possible to ensure that the same type of coolant
ility
ot p
additive is filled: always determine anti-freeze protection using
wit
, is n
the scale for G13.

h re
hole
♦ Frost protection must be guaranteed down to -25°C as a min‐ spec

es, in part or in w
imum and, in countries with arctic conditions, down to approx. t to the co

-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
rrectness of i
the cooling effect will be impaired.

l purpos
♦ Do not reduce the coolant concentration by adding water even

in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
nf
ercia
orm
♦ The temperature reading on the refractometer corresponds to

m
atio
m
the »ice flocculation point«. Flakes of ice may start forming in

o
n in
c
the coolant below this temperature.

or
thi
te
sd
a
♦ Never reuse old coolant.

iv
o
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rp
cu
o
♦ Use only a water/coolant additive mixture as a slip agent for

f
en
ng
t.
coolant hoses.
yi Co
Cop py
t. rig
gh ht
yri
Recommended mixing ratios (use only distilled water for mixing):
p by
co Vo
by lksw
cted agen
Prote AG.
Frost Anti-freeze Coolant ad‐ Distilled wa‐
protection to proportion ditive 1) ter 1)
-25°C 40% 3.2 l 4.8 l
-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending on the vehicle
equipment.

– Install lower coolant hose and secure with retaining clip

-arrow-.
– Connect coolant hoses on engine oil cooler and coolant cir‐
culation pump 2 - V178- .
– Install noise insulation: ⇒ General body repairs, exterior; Rep.
gr. 50 ; Underbody panel; Removing and installing underbody
panels .
With cooling system charge unit - VAS 6096- :
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
Without cooling system charge unit - VAS 6096- :
– Slowly fill coolant in up to Vupper marking of hatched field on

olkswagen AG
expansion tank. swagen AG. does
k not
y Vol gu
– Fit expansion
se
d b tank cap. ara
nte
ri
satelettronica
ho e
– Startauengine
t and keep engine speed at approx. 2000or arpm
c
for
about 3 minutes.
ss
ce
e
nl
pt
du
– Then run engine at idling speed until radiator fan cuts in.
an
itte
y li
erm
ab
– Check coolant level and top up as needed. When engine is at

ility
ot p
normal operating temperature, the coolant level must be at the

wit
upper mark; when engine is cold, in the middle of the shaded

, is n
h re
field.
hole
spec
es, in part or in w
t to the co
1.3 Checking cooling system for leaks

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re

hole
spec

es, in part or in w
t to the co
♦ Cooling system tester - V.A.G 1274 B-

rrectness of i
Note
l purpos
To perform the leakage test correctly, first run a self-test on the

cooling system tester - V.A.G 1274 B- .
nform
mercia
at
Self-test of cooling system tester - V.A.G 1274 B-

om
ion
c
in t
r
– Operate cooling system tester - V.A.G 1274 B- several times.

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Build up a pressure of 3.0 bar on cooling system tester .

– Observe pressure on pressure gauge of cooling system tester
for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
not be used.
Checking cooling system for leaks

• Coolant temperature at least 40 °C
WARNING
On a warm engine, the cooling system is under high pressure.

satelettronica
Skin and other parts of the body may be scalded.
♦ Reduce excess pressure by covering cap of coolant ex‐
pansion tank with cloths and opening it carefully.
– Open cap -1- on coolant expansion tank.

AG. Volkswagen AG d
agen oes
lksw not
– Fit cooling d bysystem tester - V.A.G 1274 B- with
Vo gu adapter -
ara
V.A.Gori1274/8-
se to coolant expansion tank. nte
eo
h
ut ra
– Build
ss a up pressure of approx. 1.5 bar using hand pump c of cool‐
ing system tester.
ce
le
un
pt
an
d
• The pressure must not drop by more than 0.2 bar within 10 mi‐
itte
y li
erm
nutes.
ab
ility
ot p
– If the pressure drops by more than 0.2 bar, locate and rectify
wit
is n
leaks.
h re
ole,
spec
t to the co
Note
The pressure drop of 0.2 bar within 10 minutes depends on the

rrectne
how far the coolant can cool down. The colder the engine, the
lower the pressure drop.
ss o
cial p
f in
WARNING
form
mer
atio
m

o
n
c
i
or
n thi
Skin and other parts of the body may be scalded.

te
sd
iva
o
r
• Release pressure by pressing pressure relief valve on

p
cum
r
fo
cooling system tester until the gauge shows a pressure of

en
ng
t.
yi
0.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4-cylinder common rail engine (2.0 AG. VolkGen
gl,enEA189
swagen AG
II) - Edition
does 06.2019
swa k not
Vol gu
d by ara
Check pressure relief valve in cap. ris
e nte
utho eo
ra
– Fit cooling system B- with adapter - testerss-aV.A.G 1274 c
V.A.G 1274/9- onto coolant filler cap.
ce
le
un
pt
an
d
– Using hand pump of cooling system tester, build up pressure
itte
y li
and check the opening pressure of the filler cap.
rm
ab
pe
ility
ot
Colour of filler cap Opening pressure
wit
, is n
h re
hole
blue 1.4 … 1.6 bar
spec
es, in part or in w
black 1.6 … 1.8 bar
t to the co
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
satelettronica
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 217
⇒ “2.2 Removing and installing coolant pump”, page 218
⇒ “2.3 Removing and installing 4/2-way valve with thermostat”,
page 219
⇒ “2.4 Removing and installing coolant temperature sender”,
page 224
2.1 Assembly overview - coolant pump, thermostat
1 - Coolant pump
⇒ page 218 n AG. Volkswagen AG do
lkswage es n
o ot g
2 - 15 Nm d byV ua
ran
ir se tee
satelettronica
3 - O-ring utho
or
a ac
❑ Renew ss
ce
le
un
pt
4 - O-ring
an
d
itte
y li
❑ Renew
rm
ab
pe
ility
5 - 4/2-way valve with thermo‐
ot
wit
, is n
stat
h re
hole
❑ The thermostat is loca‐
spec
es, in part or in w
ted within the 4/2-way
t to the co
valve and cannot be ex‐
changed individually.
rrectness of i
⇒ page 219
l purpos
6 - 15 Nm
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 217

2.2 Removing and installing coolant pump

equipment required
AG. Volkswagen AG d
agen oes
ksw
satelettronica
ol not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
♦ Refractometer - T10007A-
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi
Removing
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note cted agen
Prote AG.
Renew gaskets and seals.


– Remove coolant pump securing bolts -1- and carefully remove

coolant pump -2-.
Installing
note the following:
– Coat new O-ring -3- with coolant.

– Insert coolant pump -2- into cylinder block and tighten securing
bolts -1- to 15 Nm.
Note
The coolant pump plug faces downwards.
satelettronica
– Install toothed belt ⇒ page 133 .
2.3 Removing and installing 4/2-way valve

with thermostat
AG. Volkswagen AG d
Note agen oes
o lksw not
V gu
d by ara
e
The thermostat is located within the t4/2-way
ho
ris
valve and cannot be nte
eo
renew individually. s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

swage es n
Special tools and workshop by Vo lk ot g
ua
equipment required ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
satelettronica
thi
te
sd
iva
o
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o
m
f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ 10 mm jointed spanner - 3185-

♦ Multi-point bit - T10058-
Removing
Note
Renew gaskets and seals.

pipe ⇒ page 293 .

– Unscrew securing bolts -arrows- and remove battery carrier.
satelettronica
er. To do this, press release buttons.
– Free vacuum hoses -arrows- at air pipe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Unscrew bolt -2-, swing air pipe with intake connecting pipe to
erm
ab
rear and remove from turbocharger.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Unclip wiring harness from bracket -arrow-.

atio
om
n in
or c
thi
te
sd
iva
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Clear away wiring harnesses -arrows- and electrical connector

-1- from bracket.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Free electrical lines and hoses on left air pipe using removal
lever - 80 - 200- .
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Pull off coolant hoses. To do this, release hose clips -1-.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Unscrew bolts -arrows- and pull front coolant pipe to one side
away from 4/2-way valve.

– Pull coolant pipe out of connection -C- for 4/2-way valve.

Leave in its fitting location. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Free coolant hose -3-.
rrectness of i
l purpos

air pipe.
nf
ercia
or
satelettronica
m
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
m
atio
m
nator; Removing and installing alternator .

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

to side.

AG. Volkswagen AG d
– Pull coolant hoses off connections -A, B and D-. agen oes
olksw not
V gu
by ara
– Unscrew securing bolts -3- for 4/2-way valve -2-.
rised
nte
ho eo
ut
– Pull out valve from cylinder block. ss a ra
c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
2.4 Removing and installing coolant temper‐
rrectne
ature sender
s
⇒ “2.4.2 Removing and installing radiator outlet coolant temper‐
s o
cial p
ature sender G83 ”, page 225
f inform
mer
⇒ “2.4.1 Removing and installing coolant temperature sender G62
atio
”, page 224
om
satelettronica
c
i
or
n
2.4.1 Removing and installing coolant temper‐
thi
te
sd
a
ature sender - G62-

iv
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
• Engine cold.
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
sulation .

AG. Volkswagen AG d
agen oes
Vol
ksw not
gu
by ara
ed
– Free electricalhowiring
ris and hoses on left air pipe using removal
nte
eo
lever - 80 - 200-
au
t . r ac
ss
– Loosen hose clip -3- and press left air pipe with coolant pipe
ce
le
un
pt
aside.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull connector -4- off coolant temperature sender - G62- .
rrectness of i
l purpos
Note
nform
ercia
Place a cloth under connecting piece to absorb escaping coolant.

m
a
com
tio
– Pull off retaining clip -3- and pull coolant temperature sender
n in
satelettronica
r
- G62- out of screw connection.

te o
thi
s
iva
do
Installing
r
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cum
fo
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Cop py
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rig ht
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♦ Renew O-ring.
♦ Insert new coolant temperature sender - G62- immediately in‐
to union to avoid loss of coolant.
– Check coolant level ⇒ page 209 .
2.4.2 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.

– Loosen bolt -1-.

– Undo bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
– Pull connector -2- off radiator outlet coolant temperature send‐
satelettronica
er - G83- .
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♦ Renew O-ring.
♦ Insert new coolant temperature sender - G83- immediately in‐
ss
to coolant pipe at radiator outlet to avoid loss of coolant.

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mer
– Check coolant level ⇒ page 209 .

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3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 227
⇒ “3.2 Removing and installing coolant pipes”, page 228
3.1 Assembly overview - coolant pipes
1 - Grommet
❑ Not available as a sepa‐
rate part
2 - Sleeve
❑ Not available as a sepa‐
rate part
3 - 1.5 Nm
4 - 40 Nm
5 - Bracket
❑ For coolant circulation
satelettronica
pump 2 - V178-
6 - Front coolant pipe
⇒ page 228 AG. Volkswagen AG d
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12 - Radiator outlet coolant

t to the co
temperature sender - G83-

⇒ page 225
rrectness of i
13 - 9 Nm
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14 - 9 Nm
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15 - 9 Nm
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16 - Coolant line
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17 - Seal
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20 - Radiator outlet coolant - G62-

21 - Double stud 9 Nm
❑
3. Coolant pipes 227

22 - 9 Nm
23 - Retaining clip
24 - Left coolant pipe
25 - 9 Nm
26 - 9 Nm
27 - 9 Nm
28 - 13 Nm
29 - Upper front coolant pipe
30 - Coolant circulation pump 2 - V178-
Caution
After fitting a new coolant
circuit pump, it is essen‐
tial to bleed the cooling
satelettronica
system using the VAS
6096 ⇒ page 209 . If this
is not done, air inclusions
can cause consequential en AG. V
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⇒ “3.2.1 Removing and installing front coolant pipe”, page 228

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⇒ “3.2.2 Removing and installing upper front coolant pipe”,

page 232
t to the co
⇒ “3.2.3 Removing and installing left coolant pipe”, page 233

rrectne
⇒ “3.2.4 Removing and installing right coolant pipe”, page 235
3.2.1 Removing and installing front coolant

ss o
pipe
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♦ Hose clamps, up to 25 mm - 3094- for vehicles with dual clutch

gearbox
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– Unscrew bolts -arrows- and remove battery tray -1-.

rrectness of i
er. To do this, press release buttons.

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– Free wiring harnesses -arrows- and electrical connector -1- at
bracket.

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-2-.

lever - 80 - 200- .
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– Loosen hose clips -2- -3- and pull coolant hoses off.
– Unscrew bolts -arrows- and pull front coolant pipe out of 4/2-
way valve.
Installing
Note
♦ Renew gaskets, seals and O-rings.

oil and grease before installation. agen
AG. Volkswagen AG d
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♦ Secure all hose connectionssewith
d b hose clips corresponding to
gu
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parts catalogue . nte
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ce
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– Push front coolant pipe into 4/2-way valve.
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– Electrical connections and routing ⇒ Current flow diagrams,
h re
Electrical fault finding and Fitting locations.
hole
spec
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3.2.2 Removing and installing upper front
rrectness of i
coolant pipe
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Removing
– Loosen hose clips -1- -3- and pull coolant hoses off.
– Remove top coolant pipe at front.
Installing
3.2.3 Removing and installing left coolant pipe
satelettronica
AG. Volkswagen AG d
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♦ Hose clamps to 25 mm - 3094- hor eo
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mer
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233
AG.
3. Coolant pipes
AG. Volkswagen AG d
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♦ Spring-type hoclip
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hole
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– Clear away wiring harnesses -arrows- and electrical connector

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-1- from bracket.

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– Loosen hose clips -1- and -2- and remove air hose.

– Unscrew bolts -2-, -5- and -arrows-.

lever - 80 - 200- .
– Place drip tray - VAS 6208- beneath engine.
– Clamp off coolant hoses with hose clamps -3094- and loosen
hose clamps -1- and -4-.
– Pull coolant hoses off left coolant pipe.

– Remove left coolant pipe.
Installing
• Specified torques: ⇒ page 227
satelettronica
Note
♦ Secure hose connections with hose clips in such a way that
AG. Volkswagen AG d
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– Electrical connections and routing ⇒ Current flow ddiagrams,
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– Add coolant ⇒ page 209 . ss c
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3.2.4 Removing and installing right coolant

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pipe
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– Loosen bolt -1- and remove bolt -2- and nut -3-.
hole
spec
es, in part or in w
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
t to the co
with fuel hoses -5- and -6- connected.

rrectness of i

sulation .
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– Pull connector -3- off radiator outlet coolant temperature send‐
er - G83- .
– Clamp off coolant hoses with hose clips -3094- .
– Loosen hose clip -arrows- and pull coolant hoses off right
coolant pipe.
– Unscrew nut -1- and bolt -2- and remove right coolant pipe.
Installing
satelettronica
AG. Volkswagen AG d
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Secure hose connections with hose clips in thorsuch
is
a way that fac‐ nte
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4 Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 238
⇒ “4.2 Removing and installing radiator”, page 239
⇒ “4.3 Removing and installing radiator cowl with radiator fan”,
page 240
4.1 Assembly overview - radiator/radiator fan
1 - Radiator/cooler
⇒ page 239
❑ After renewing, renew
entire coolant.
AG. Volkswagen AG d
2 - O-ring lksw
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3 - Upper coolant hose aut
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coolant hoses
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⇒ page 208
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4 - Cap
ility
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❑ Check using cooling
is n
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system tester -
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spec
V.A.G 1274- and adapt‐
er - V.A.G 1274/9-
t to the co
⇒ page 213 .
5 - Connector
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6 - 5 Nm
s
7 - Expansion tank
s o
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❑ Checking cooling sys‐
inform
tem for leaks with cool‐
mer
ing system tester -
atio
m
V.A.G 1274- and adapt‐

o
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c
er - V.A.G 1274/8- i
or
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⇒ page 213
t
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8 - Lower coolant hose

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t.
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coolant hoses
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⇒ page 208
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10 - 5 Nm
11 - Radiator fan - V7-
12 - Right radiator fan - V35-
13 - Connector
14 - Cowling

4.2 Removing and installing radiator

equipment required
satelettronica
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– Pull off connector for radiator fan.
agen
Prote AG.
– Remove cowling together with fans ⇒ page 240 .

– Remove radiator securing bolts ⇒ Item 10 (page 238) and re‐
move radiator upwards.
Installing
note the following:
4. Radiator, radiator fan 239

4.3 Removing and installing radiator cowl

with radiator fan
Removing
pipe ⇒ page 293 .
– Unscrew upper bolts -top arrows- of air cowling.
sulation .
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– Remove connecting hose »hot side« to charge air pipe. To do

un
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this, loosen hose clamps -1- and -2-.

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– Unscrew lower bolts -lower arrows-.

atio
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– Remove cowling with radiator fans upwards.

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– Expose connector -1- and (if present) -2- and wiring.

– Unscrew nuts -arrows- and remove radiator fan.
Installing
Install in reverse order.

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “2 Safety information”, page 3
⇒ “3.1 Rules for cleanliness”, page 7
⇒ “1.1 Assembly overview - turbocharger”, page 241
⇒ “1.2 Removing and installing turbocharger”, page 243
⇒ “1.3 Renewing vacuum unit for turbocharger”, page 247
1.1 Assembly overview - .turbocharger

gen AG
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♦ Charge air system must be free of leaks.

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♦ Renew self-locking nuts.
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♦ Before screwing on oil supply line, fill turbocharger at connec‐
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tion with engine oil.
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spec
♦ After installing turbocharger, run engine for about 1 minute at
t to the co
idling speed to ensure that oil is supplied to turbocharger.
rrectness o
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1. Turbocharger 241

pipe
❑ With flexible joint; do not
bend flexible joint - risk
of cracking
2 - Seal
❑ Renew agen
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❑ Tighten union nuts to
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22 Nm.
t to the co
5 - Oil return line
satelettronica
6 - Seal
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❑ Renew
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7 - 24 Nm
nf
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8 - Heat shield
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9 - Turbocharger
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❑ Can only be renewed

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manifold and vacuum
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⇒ page 243
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❑ Installation possible in
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one position only.

11 - O-ring
❑ Renew
12 - Pulsation damper
13 - 9 Nm
14 - Intake connecting pipe
15 - 9 Nm
❑ Attached in inlet connection.
16 - O-ring
❑ Renew
17 - Bracket
18 - 15 Nm
19 - Heat shield
20 - Seal
❑ Renew
21 - 24 Nm
❑ Renew
242 Rep. gr.21 - Turbocharging/supercharging

22 - Exhaust gas temperature sender 1 - G235-

❑ Assembly overview ⇒ page 375 .
23 - 20 Nm
24 - Support
❑ for turbocharger
25 - 9 Nm
26 - O-ring
❑ Various diameters.
❑ Renew
27 - Banjo bolt; 40 Nm
❑ Renew
28 - O-ring
❑ Renew
29 - Banjo bolt; 30 Nm
30 - O-ring
AG. Volkswagen AG d
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1.2 Removing and installing turbocharger
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mer
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Fit heat shield sleeve in the same place when installing.
lksw
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– Observe rules for cleanliness ⇒ page 7 .
1. Turbocharger 243
AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golfut 2009 ➤ , Golf Plus 2009 ➤ , Passat 2011 ...
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If a mechanical fault is discovered on the turbocharger (e.g. a
, is n
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destroyed compressor impeller), it is not sufficient to just renew
hole
the turbocharger. To avoid any subsequent damage, the fol‐
spec
lowing work must be carried out: es, in part or in w
t to the co
♦ Check air filter housing, air filter element and air inlet ho‐
ses for contamination.
rrectness of i
♦ Check the whole charge air path and charge air cooler for
foreign objects.
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♦ If foreign objects are discovered in the charge air system,

clean the charge air path and, if necessary, renew the
nf
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o
charge air cooler.
rm
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– Remove particulate filter ⇒ page 347 .
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– Expose vacuum hoses -arrows- at air pipe.
op Vo
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Prote
AG.
and pull off from turbocharger.
– Remove heat-shield sleeve.

– Pull vacuum hose -2- off turbocharger vacuum unit.
– Separate vacuum hose -3-.
– Disconnect electrical connector -1- at position sender for
charge pressure positioner - G581- .

– Free electrical connector -3- for exhaust temperature sender

1 - G235- and electrical line.
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– Open hose clip -1- and remove pulsation damper -2-.
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– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐ by c lksw
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lation.
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– In vehicles with an auxiliary heater, remove the brackets for

the coolant lines leading to the auxiliary heater from the cylin‐
der block or transfer gearbox and the oil sump.
Vehicles with front-wheel drive
Note
The oil supply line may be bolted on the top or bottom of the tur‐
bocharger. In the case of some vehicle types (such as Touran or
Golf Plus), the plenum chamber bulkhead must be removed in
order to allow for the removal of the oil supply line bolted to the
top of the turbocharger ⇒ General body repairs, exterior; Rep.
gr. 50 ; Plenum chamber bulkhead; Assembly overview – plenum
chamber bulkhead .
1. Turbocharger 245
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4,
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– Unscrew bolts -1- and -3- and banjo bolt -4-.
– Open connection to oil supply line, separate support from oil
rrectness of i
supply line and remove.
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– Undo oil supply line -2- at turbocharger.
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– Unscrew bolts -arrows- and remove heat shield.

– Unscrew nuts -arrows-.

– Remove turbocharger together with exhaust manifold from
cylinder head and turn so that intake side is facing downwards.
Remove turbocharger together with exhaust manifold down‐
wards.
Installing
⇒ “1.1 Assembly overview - turbocharger”, page 241 .
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Secure hose connections with
agen hose clips in such
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♦ After installing hturbocharger,
or
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nteat
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idling speeds ato
ut ensure that oil is supplied to turbocharger. Door a
not rev engine immediately.
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– Install exhaust gas recirculation pipes ⇒ page 381 .

spec
– Connect vacuum hoses ⇒ page 264 .

t to the co

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s

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– Carry out basic setting for turbocharger ⇒ Vehicle diagnostic

nform
tester
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1.3 Renewing vacuum unit for turbocharger

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1. Turbocharger 247
♦ Socket 10 mm - T10422- or socket 10 mm - T10422 A-
♦ Ring spanner 10x12 - T10423-
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rrectne
♦ Red paint, e. g. touch-up pencil “Mars Red” - L 0A3 A01-

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The special tools indicated, in particular the 10 mm socket in‐

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A spare-parts kit is available ⇒ Electronic parts catalogue (ETKA)
for replacing the vacuum unit with position sender for charge
pressure positioner - G581- .

Removing
– Open heat-protection mat and disconnectagen
electrical
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– Remove crankcase breather connecting pipe-1- from cylinder
head cover by pressing release buttons.
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– Move clear vacuum hoses -arrows-.
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– Unscrew bolt -2- (captive), swing air pipe with inlet connection
to rear and pull off from turbocharger.
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– Seal opening in turbocharger with the sealing cap from the
m
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spare-parts kit.
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– Pull vacuum line off vacuum unit.

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Note
The securing bolts of the vacuum unit may have an M6 hexagon

head or M8 hexagon socket head. The tightening torque is the
same for either one.
– Unscrew securing bolts of the vacuum unit -arrows- and re‐

move the vacuum unit with position sender for charge pres‐
sure positioner - G581- -A-.
Installing
Caution
Only use new bolts and nuts from the spare-parts kit!
– If necessary, remove lower securing nut of the control rod from

the new vacuum unit.
– Screw locknut by hand onto the control rod as far as possible
in the direction of the vacuum unit.
1. Turbocharger 249
– Push control rod through the adjusting lever, fit vacuum unit
with position sender for charge pressure positioner - G581-
-A- and tighten fastening bolt.
– Tighten securing bolts -arrows- to 8 Nm.
Note
Make sure that the guiding element moves easily along the con‐
trol rod.
– Connect connector -arrow- to the position sender for the

charge pressure positioner - G581- and close the heat pro‐
tection mat.
– Connect vehicle diagnostic tester .
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es, in part or in w
bocharger, actual input voltage” and switch until measured

t to the co
value is displayed.
– Connect hand vacuum pump - VAS 6213- to vacuum unit.
rrectness of i
– While observing the displayed measured value, set a voltage

of 760 mV by creating a vacuum of max. 0.65 bar.
l purpos
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Caution
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During the following procedure for adjusting the control rod,

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spec
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Caution
Create a partial vacuum of 0.65 ± 0.05 bar to act on the vacuum
rrectne
unit in order to ensure that the adjusting lever rests against the
»stop«. When this is done, the voltage should automatically be
s
set to 760 mV.
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Voltage OK.
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– Press locking plate by hand onto the control rod and, if possi‐
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– Mark body of vacuum unit with a dot of red colour where it can
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be clearly seen, using e. g. touch-up pencil “Mars Red” - L 0A3
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– Counterhold locknut -B-, undo securing nut -A- of the control

rod and correct the voltage by turning the locknut -B-.
– Counterhold locknut -B-, turn securing nut -A- in opposing di‐
rection and tighten it with socket AF 10 - T10422- or socket AF
10 - T10422 A- .
1. Turbocharger 251
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Mark body of vacuum unit with a dot of red colour where it can
be clearly seen, using e. g. touch-up pencil “Mars Red” - L 0A3
A01- .
Continuation
– Remove sealing cap from turbocharger.
– Re-install all engine components.
– Start engine and clear event memory ⇒ Vehicle diagnostic
tester .
– Check setting as follows:
Selecting diagnostic function:
– Click the button “006 - Basic setting” on the display.
– Select “Adaptation of turbocharger” from selection list.
– Click the button “Measured values” on the bottom right on the
display.
satelettronica
– Select “Positioner for high pressure, turbocharger, actual input
voltage” from selection list.
– Click the “Start” button on the bottom right on the display.
– Observe value in lower window. It must fluctuate between
650 … 850 mV and 3000 … 3400 mV (vacuum unit is moved
to both end stops alternately).
If voltage values are OK:
– End basic setting procedure.
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252
AG.
Rep. gr.21 - Turbocharging/supercharging
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 253
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 254
⇒ “2.3 Removing and installing charge air cooler”, page 254
⇒ “2.4 Removing and installing charge pressure sender”,
page 256
⇒ “2.5 Checking charge air system for leaks”, page 256
2.1 Assembly overview - charge air system
1 - Air intake hose

❑ »Hot« side, top
2 - Left air pipe
❑ »Hot« side
3 - Sleeve
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9 - Seal
10 - 5 Nm
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11 - Mountings
12 - Mountings
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❑ »Cold« side, bottom

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14 - Air intake hose

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15 - Air pipe (right side)

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17 - Charge air pressure sender - G31- / intake air temperature sender - G42-
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18 - O-ring
❑ Renew
2. Charge air system 253

Installing air hoses with screw-type clips
Note
In order to be able to securely attach the air ducts on their con‐

nections, the screws of the used hose clips have to be sprayed agen
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Specified torques for au
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1- Hose clip -a- = 13 mm wide: 5.5 Nm
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2- Hose clip -b- = 9 mm wide: 3 Nm
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Note
♦ Check all air hoses and pipes to make sure they are firmly
rrectness of i
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seated and not leaking before carrying out tests or repairs.
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♦ In order to be able to securely attach the air ducts on their
or
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The screw-type clips -A- on the charge air lines must always cted agen
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be tightened as specified ⇒ page 254 . If the torque is too low
or too high, the charge air hose may slip off the corrugated pipe
connection or the charge air pipe when the vehicle is used.
Installing air hoses with screw-type clips

Specified torques for
1- Hose clip -a- = 13 mm wide: 5.5 Nm
2- Hose clip -b- = 9 mm wide: 3 Nm
2.3 Removing and installing charge air cool‐

er
Removing
– Removing radiator ⇒ page 239 .

– Remove front bumper cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Front bumper; Removing and installing front
bumper .
– Unbolt air ducts on left and right from charge air cooler.
– Loosen hose clamps -1- and -2- and remove air hose.
WARNING
Danger of injury due to coolant.

♦ Do not open the air conditioner refrigerant circuit.
Caution
Danger of damage to condenser, refrigerant lines and hoses.

– Unscrew bolt from refrigerant line retaining clamp next to lon‐
satelettronica
gitudinal member.
– Unscrew bolts -1- for charge air cooler and -2- for condenser.
– Swing charge air cooler backwards slightly.
AG. Volkswagen AG d
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– Unscrew bolt from lower right refrigerant line bracket on

charge air cooler.
– Swing condenser forwards into opening on lock carrier.
– Detach charge air cooler upwards out of lock carrier and re‐
move diagonally downwards.
Installing
⇒ “2.1 Assembly overview - charge air system”, page 253 .
Note
– Install condenser ⇒ Rep. gr. 87 ⇒ Heating, air conditioning
satelettronica
system; Rep. gr. 87 ; Refrigerant circuit; Removing and in‐
stalling condenser .
AG. Volkswagen AG d
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– Install front bumper cover ⇒ General body repairs, exterior;olks
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Rep. gr. 63 ; Front bumper; Removing and installing efront
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– Installing radiator ⇒ page 239 . ss c
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2.4 Removing and installing charge pres‐

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sulation .
– Detach connector -2- from sender.
– Unscrew bolts -1- and pull charge pressure sender - G31- / rrectne
intake air temperature sender - G42- out of air pipe.
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Installing
inform
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atio
⇒ “2.1 Assembly overview - charge air system”, page 253 .

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– Install noise insulation ⇒ General body repairs, exterior; Rep. Prote AG.
tion .
2.5 Checking charge air system for leaks


♦ Charge air system tester - V.A.G 1687- with adapter - V.A.G

1687/12-
Procedure AG. Volkswagen AG d

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– Remove engine cover panel b⇒ y Vpage 9 .
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– Loosen hose clip -3- and
ut
ho remove air hose from air filter hous‐ eo
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ing. ss a c
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– Insert adapter - 1687/12- into intake hose -1- and secure with
rrectness of i
a clip.
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Prepare charge air system tester - V.A.G 1687- as follows:

nform
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– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

– Connect charge air system tester - V.A.G 1687- to adapter -

1687/12- as shown.
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– Connect compressed air hose -1- (compressed air supply) to
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charge air system tester - V.A.G 1687- .
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If there is water in inspection glass, drain via drain screw -6-.
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– Open valve -3-.
rrectness of i
– Set pressure to 0.5 bar with pressure control valve -2-.
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The pressure must not exceed 0.5 bar. If the pressure is too
m
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high this can cause damage to the engine.

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– Open valve -4- and wait until test circuit is full. If necessary,
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regulate pressure to 0.5 bar.
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♦ using standard leak detecting spray

♦ Ultrasonic tester - V.A.G 1842-
Note
♦ Slight leaks on the intake side of turbocharger are permissible,

as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
♦ If a leak has been located, observe notes for charge air system
when carrying out any repair work.
♦ Depressurise test circuit by detaching coupling from adapter -
1687/10- before removing adapter.
Installing
Note
♦ Renew the seal and O-ring.

– Installing inlet connection and pulsation damper ⇒ page 241 .


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23 – Mixture preparation - injection
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1 Injection system
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⇒ “1.1 Schematic overview - fuel system”, page 260
h re
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spec
⇒ “1.2 Filling/bleeding fuel system”, page 262
t to the co
⇒ “1.3 Checking fuel system for leaks”, page 263
1.1 Schematic overview - fuel system
rrectne
WARNING
ss o
cial p
f in
♦ Read rules for cleanliness and the instructions for working
form
mer
on the fuel system ⇒ page 7 .
atio
m
♦ Always follow these rules for cleanliness and instructions

o
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before starting work and while working on the fuel system.
thi
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♦ If components of the fuel system between the tank and the

i
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pr
cum
r
high-pressure fuel pump are removed or renewed, the fuel

fo
satelettronica
en
ng
system must be filled to be bled ⇒ page 262 . (It is im‐

t.
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op
portant not to allow the high-pressure pump to run while C py
t. rig
still empty.)
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The diesel direct injection system control unit is equipped with an

event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester .
260 Rep. gr.23 - Mixture preparation - injection

1 - Fuel
❑ With fuel system pres‐
surisation pump - G6-
2 - Fuel filter
❑ With pre-heating valve
❑ ⇒ Rep. gr. 20 ; Fuel fil‐
ter
3 - Supplementary fuel pump -
V393- or fuel pump 2 - V277- n AG. Volkswagen AG do
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❑ Only in vehicles with 0.5 byV
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ua
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Removing and installing ⇒ ss
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Rep. gr. 20 ; Fuel pump; Re‐
ce
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moving and installing fuel
pt
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pump .
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Note
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The component designation for the
spec
inline electronic fuel pump was
satelettronica
es, in part or in w
t to the co
changed from “supplementary
pump V393” to “fuel pump 2 V277”
in a software revision. This is the
rrectness of i
same component.
l purpos
4 - Filter strainer
❑ Only in vehicles with 0.5
nform
ercia
bar fuel system

m
at
5 - Fuel temperature sender -
om
io
G81-
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❑ After renewing, a first cum

for
fuel filling must be per‐

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formed (never allow the Cop py
pump to run while it is still empty) ⇒ page 262 .
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7 - Fuel metering valve - N290-
❑ Must not be removed.
8 - Fuel pressure regulating valve - N276-
❑ Installing and removing ⇒ page 296
9 - High-pressure accumulator (rail)
10 - Fuel pressure sender - G247-
11 - Non-return valve
❑ The non-return valve must be renewed only as a unit together with the fuel return lines.
❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
12 - Injectors
❑ Injector, cylinder 1 - N30-
1. Injection system 261

1.2 Filling/bleeding fuel system
Caution
Risk of irreparable damage to high-pressure pump if allowed

to run dry.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. Do not run the high-pressure pump
while empty.
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior
wage
nto
AGinstallation
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AG do
fuel lines.
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♦ Vehicle must have fuel. ho
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satelettronica
t
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c
ss
Proceed as follows to fill high-pressure pump with fuel.
ce
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nl
pt
du
an
– Switch on ignition.
itte
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erm
ab
– Connect vehicle diagnostic tester and perform the guided
ility
ot p
function “Bleeding fuel system” or “Filling/bleeding fuel sys‐
wit
, is n
tem” depending on software version.
h re
hole
spec
es, in part or in w
t to the co
Note
The fuel pumps will now be actuated for a total of three minutes. rrectness of i
l purpos
– Start engine.
– After filling fuel system, leave the engine running at moderate
nform
ercia
speed for a few minutes and then switch it off again.

m
– Check fuel system for leaks.

at
om
ion
c
– Read out event memory and, if necessary, delete event mem‐

in t
or
his
e
ory entry ⇒ Vehicle diagnostic tester .

at
do
priv
– Road-test vehicle extensively. Accelerate with full throttle at

um
for
least once, and then check high-pressure section again for

en
ng
t.
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leaks. t. Cop py
rig
gh ht
pyri by
Vo
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by c lksw
Note cted agen
Prote AG.
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch off engine and
clear event memory. Then continue with a road test.
– Read event memory again.
Note
– Read event memory.

1.3 Checking fuel system for leaks

– Allow engine to idle for a few minutes but do not accelerate.
Then switch off engine again. Fuel system will bleed itself au‐
tomatically.
– Check fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– Then road-test the vehicle. Accelerate with full throttle at least
once, then check the high-pressure section again for leaks.
Note
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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mer
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1. Injection system 263

2 Vacuum system agen

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⇒ “2.1 Assembly overview - vacuum system”, pagee264db
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⇒ “2.2 Checking vacuum system”, page 264 aut ho eo
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2.1 Assembly overview - vacuum system
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Caution
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Do not kink, twist or crush the vacuum lines when routing vac‐
h re
hole
uum lines. This may cause breakdowns.
spec
es, in part or in w
t to the co
1 - Pressure canister
rrectness of i
❑ On turbocharger.
l purpos
❑ With position sender for

charge pressure posi‐
tioner - G581-
nf
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or
satelettronica
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2 - Charge pressure control
m
atio
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solenoid valve - N75-

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3 - Silencer
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4 - Air filter
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5 - To brake servo
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6 - Connection piece
rig
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❑ On vacuum pump
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7 - Non-return valve
sition
cooler changeover valve -
N345-
9 - Cylinder head cover
10 - Vacuum unit
❑ For changeover for ex‐
haust gas recirculation
cooler.
2.2 Checking vacuum system
Caution
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.


♦ Hand operated vacuum pump - VAS 6213-
AG. Volkswagen AG d
agen oes
olksw not
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⇒ “2.2.1 Checking supply line, vacuum reservoir andoris non-return
e nte
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valve”, page 265 aut
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⇒ “2.2.2 Checking control line to turbocharger”, page 266
ce
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nl
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du
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⇒ “2.2.3 Checking control line to vacuum unit for exhaust gas re‐
itte
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circulation cooler changeover function”, page 267
ab
ility
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2.2.1 Checking supply line, vacuum reservoir
wit
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and non-return valve
hole
spec
es, in part or in w
t to the co
– Unclip exhaust gas recirculation cooler changeover valve -
N345- from bracket on intake manifold.
rrectness of i
– Detach vacuum hose at lower connection -arrow in I- from ex‐
l purpos
haust gas recirculation cooler changeover valve - N345- and

from charge pressure control solenoid valve - N75-
-arrow in II-.
nf
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orm
– Seal open hose ends with suitable plugs.
m
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Note
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Do not use screws or threaded bolts. m

f
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t.
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Cop py
.
– Pull vacuum hose -arrow- off vacuum pump connection.
ht rig
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2. Vacuum system 265

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CC 2010 ➤ , Eos 2006 ir se ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat
d ran
tee 2011 ...
o
4-cylinder common authrail engine (2.0 l, EA189 Gen II) - Edition 06.2019or
ac
ss
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– Connect hand vacuum pump - VAS 6213- to removed hose
un
pt
an
and generate a vacuum of 0.6 bar.
d
itte
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ab
– Watch gauge of hand vacuum pump for about 30 sec.
ility
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• Vacuum must not drop.
is n
h re
ole,
If vacuum drops:
spec
– Find damage or leaking connections in hose line and replace
t to the co
that section of hose.
If pressure does not drop:
rrectne
– Pull hose off hand vacuum pump - VAS 6213- .
ss
– Remove one of the plugs from hose ends.
o
cial p
f in
– If the non-return valve functions properly, a clear hiss is audi‐
form
mer
ble when vacuum in vacuum reservoir is released.
atio
om
If no hiss is audible:
n
c
i
or
n thi
e
– Replace non-return valve.

t
sd
iva
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pr
c
If a hiss is audible:
um
r
fo
en
ng
t.
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– Reconnect vacuum hoses.
Co
satelettronica
Cop py
t. rig
gh
– Checking control line to turbocharger ⇒ page 266 .
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2.2 Checking control line to turbocharger
– Detach hose from middle connection of charge-pressure con‐
trol solenoid valve - N75- -arrow in I- and from turbocharger
vacuum unit -arrow in II-.
– Seal hose opening with suitable plug.
Note
Do not use screws or threaded bolts.
– Connect hand vacuum pump - VAS 6213- to the other end of

the hose and generate a vacuum of 0.6 bar.
– Watch pressure gauge of hand vacuum pump for about 30
sec.
• Vacuum must not drop.
If vacuum drops:
– Renew vacuum hose.
If pressure does not drop:
– Reconnect vacuum hoses.
– Check control line to vacuum unit for exhaust gas recirculation
cooler changeover function ⇒ page 267 .

2.2.3 Checking control line to vacuum unit for

exhaust gas recirculation cooler
changeover function
– Detach hose from middle connection of exhaust gas recircu‐
lation cooler changeover valve - N345- -arrow-.
– Connect hand vacuum pump - VAS 6213- to removed hose
and generate a vacuum of 0.6 bar.
– Watch pressure gauge of hand vacuum pump for about 30
sec. Vacuum must not drop.
If the pressure drops:
– Detach vacuum hose from vacuum unit for exhaust gas recir‐
culation cooler changeover function.
– Connect hand vacuum pump - VAS 6213- with supplied vac‐
uum hose to vacuum unit and generate vacuum of 0.6 bar.
Note
satelettronica
♦ The vacuum unit control range must be perceptible and the
vacuum must not drop. If this is not the case, renew the ex‐
haust gas recirculation cooler ⇒ page 381 .
♦ If no fault can be detected on the vacuum unit, renew the vac‐
uum line from the exhaust gas recirculation cooler changeover
valve - N345- .
– Fit engine cover panel ⇒ page 9 .
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mer
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Cop py
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2. Vacuum system 267

3 Injectors/high-pressure accumulator
(rail)
⇒ “3.1 Assembly overview - injectors”, page 268
⇒ “3.2 Adapting correction values for injectors”, page 271
⇒ “3.3 Testing jammed-open injectors”, page 272
⇒ “3.4 Checking return flow rate of injectors with engine running”,
page 273
⇒ “3.5 Checking return flow rate of injectors at starter speed”,
page 276
⇒ “3.6 Removing and installing injectors”, page 277
⇒ “3.7 Removing and installing high-pressure lines”, page 281
⇒ “3.8 Removing and installing fuel rail”, page 282
3.1 Assembly overview - injectors
Caution
satelettronica
When installing a new short engine, it is compulsory to fix and AG. Volkswagen AG d
tighten the clamping jaws of the injectors with the specified agen oes
olksw not
torque after installing the high-pressure lines ⇒ page 268 . d by V gu
ara
Clamping jaws are only secured »hand-tight« for setting the orise nte
eo
auth
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of these notes may lead to damage to engine. ss c
ce
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nl
pt
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itte
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erm
ab
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spec
es, in part or in w
t to the co
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thi
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Cop py
t. rig
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pyri by
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Prote AG.

1 - Seal
❑ In cylinder head cover
⇒ page 126
2 - Copper washer
❑ Renew
3 - O-ring
❑ Renew
4 - Injector
❑ When removing and in‐
stalling, always renew
the following compo‐
nents and seals/O-
rings: “copper seal”, “O-
ring for injector bore”,
“O-ring for injector re‐
turn connection”. agen
AG. Volkswagen AG d
oes
lksw not
❑ The followingd by Vo
compo‐ gu
ara
nents
orise and seals or O- nte
satelettronica
aurings
th must always be eo
ra
s renewed when an injec‐
s c
tor is renewed: “copper
ce
e
nl
pt
du
seal”, “O-ring for injector

an
itte
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bore” and “O-ring for in‐

erm
ab
jector return connec‐

ility
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tion”
wit
, is n
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❑ Before re-using “high-

hole
pressure injection line”,

spec
es, in part or in w
inspect taper seats vis‐

t to the co
ually for damage such

as transverse scores or
corrosion; always renew
rrectness of i
if damaged.
❑ If they are to be reinstal‐
l purpos
led, the injectors, high-

pressure lines and
nform
ercia
clamping pieces must only ever be refitted on the same cylinder.

m
❑ Before installing, clean injector bore using cleaning set - VAS 6811-
at
om
io

n
c
in t
or
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e
5 - O-ring
at
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❑ Renew
um
for
en
ng
t.
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Co
Cop py
t.
❑ To fuel tank
rig
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pyri by
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❑ Must not be kinked, damaged or blocked.
co lksw
by
cted agen
Prote
❑ Do not dismantle.
AG.
❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then check
fuel return lines for leaks.
❑ Renew
8 - Clamping piece
❑ If they are to be reinstalled, the injectors and clamping pieces must only ever be refitted on the same
cylinder.
9 - High-pressure line, 28 Nm
❑ Between fuel rail and injectors.
3. Injectors/high-pressure accumulator (rail) 269

Note
♦ Observe cylinder-specific mark‐

ings if reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:
♦ Check taper seat of respective
high-pressure line for deforma‐
tion and cracks. agen
AG. Volkswagen AG d
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olks
♦ The inside of theeline
d b must be
yV t gu
ara
free of deformations,
ho
ris constric‐ nte
eo
tions and damage.
s aut ra
c
s
♦ Corroded lines should no longer
ce
le
un
pt
be used.
an
d
itte
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erm
ab
❑ Install so that component is not under tension
ility
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wit
10 - 22 Nm
is n
h re
ole,
satelettronica
11 - Fuel rail
spec
t to the co
12 - Fuel return hose
13 - Fuel pressure regulating valve - N276- , 80 Nm.
rrectne
❑ Renew after each removal
s
s o
cial p
f in
14 - O-ring
form
mer
❑ Renew
atio
om
15 - High-pressure line, 28 Nm
c
i
or
n thi
e
❑ Between high-pressure pump and fuel rail

t
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Note
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ings if reusing high-pressure pyri by
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lines.
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checks:
tion and cracks.
♦ The inside of the line must be
free of deformations, constric‐
tions and damage.
be used.
16 - 8 Nm
❑
17 - Fuel pressure sender - G247- , 100 Nm
18 - Grommet
❑ In cylinder head cover

Clamping piece installation position

• One clamping piece encompasses 2 injectors each.
• Thick part -arrow- of clamping piece points downwards.
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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erm
ab
ility
3.2 Adapting correction values for injectors
ot p
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The function “Adaptation of correction values for injectors” serves
hole
spec
to correct the injection rates for each cylinder of a common rail
es, in part or in w
system individually across the entire ignition map range.
t to the co
The 7-digit correction values -1- (details in illustration are only an
example) are marked separately on each injector. The marked
rrectness of i
values may consist of letters and/or numbers.
satelettronica
l purpos
Top view of injector

1 - Checksum
nf
ercia
o
2 - Data Matrix Code
rm
m
atio
m
3 - Part number
o
n in
or c
thi
After renewing an injector, the correction value must be written
te
sd
a
into the engine control unit.

iv
o
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rp
cu
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f
After renewing the engine control unit, the “correction values for en
ng
t.
yi
the injectors” must be transferred to the new engine control unit.
Co
Cop py
t. rig
gh
The adaptation procedure is described in Guided fault finding.
ht
pyri by
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Also check that the “injector delivery calibration values” are cor‐
cted agen
Prote AG.
rectly entered for all the other injectors. Do not attempt to re-enter
these values if the correct values are already stored in the engine
control unit.
Select correct vehicle in Guided fault finding.
– Press “GoTo” button.
– Press “Function/component selection”.
– Select “drive (Rep. Gr. 01; 10 - 39)”.
– Select respective engine code.
– “01 - Self-diagnosis compatible systems”
– Select “01 - Diesel direct injection and glow plug system
EDC 17”.
– Select “01 - Functions”.
– Select “01 - Read/adapt correction values for injectors”

3.3 Testing jammed-open injectors

AG. Volkswagen AG d
agen oes
lksw not
WARNING d by
Vo gu
ara
ise nte
or eo
h
♦ Read rules for cleanliness and the instructionss aufor
t
working ra
c
on the fuel system ⇒ page 7 . s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
satelettronica
rm
m
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om
n in
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thi
te
sd
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♦ Make an -adapter- from a return line.
f
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
– Clear fault memory entry using vehicle diagnostic tester.

– Clean all connections (e.g. with standard commercially avail‐
able cold cleaning solvent) before opening them.
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check one cylinder after the other.
– Dry all cleaned parts.

Begin with cylinder 1.

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ir se CC 2010 ➤ , Eos 2006 ➤ , Golf
tee 2009 ➤ , Golf Plus 2009 ➤ , Passat 2011 ...
t or
au 4-cylinder common rail engine
ac (2.0 l, EA189 Gen II) - Edition 06.2019
ss
ce
le
un
– Pull return line connections off at injectors. To do this, press
pt
an
d
itte
bows -1- and -2- down and simultaneously pull release pin
y li
erm
ab
upwards -arrow-.
ility
ot p
– Connect clean, blown-out adapter to injector to be tested.
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f in
– Use hand vacuum pump - VAS 6213- to generate vacuum of
form
mer
approx. -500 mbar.
atio
m
If injector is OK, pressure remains constant for 30 seconds.

o
n
c
i
or
n thi
e
If injectors are defective, the pressure drops to 0 bar within 2 … 3

t
sd
va
seconds.
i
o
pr
cum
r
fo
en
Repeat check is necessary, observe pressure loss at hand-oper‐
ng
t.
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ated vacuum pump - VAS 6213- . op
satelettronica
C py
t. rig
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– Renew defective injectors ⇒ page 277 .
pyri by
Vo
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cted agen
Prote AG.
3.4 Checking return flow rate of injectors

with engine running
Checking return flow rate of all injectors
Caution
Danger of functional impairment due to contamination/soiling

♦ Observe rules for cleanliness ⇒ page 7 .

– Open hose connection at fuel return line.

– Use a clean plug -2- to seal open return connection.

– Hold fuel return hose -1- (added an extension to it if necessary)
in measuring vessel to measure total return flow.
– Start engine and allow it to run at idling speed for 2 minutes.
• Specified amount in 2 minutes: 0 ml to 50 ml
– If the specified amount is achieved, increase the engine speed
to between 2000 and 2500 rpm for approx. 2 minutes and then
check the amount of fuel returned again.
• Specified amount in 2 minutes: less than 250 ml
Note
1000 ml is 1 litre
If more fuel is returned than the specified amount, one or more

injectors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors
satelettronica
olkswagen AG
en AG. V
Special tools and workshop equipment required olkswag does
not
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♦ Hose clamps to 25 mm - 3094- ris
ed nte
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t to the co
rrectne
♦ Return flow meter - VAS 6684-

ss o
cial p
f inform
mer
atio
om
n
c
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te
sd
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fo
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t.
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Cop py
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Prote AG.
Each injector normally has a relatively low return flow rate. If the
return flow rate of one injector is relatively high compared to those
of the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercially avail‐
able cleaning solution) before removing.
– Dry all components after cleaning.

– Clamp off fuel return hose -arrow- using hose clip up to 25 mm

- 3094- .

upwards -arrow-.
Note
Adhere strictly to rules of cleanliness. No dirt must be allowed to

get into the disconnected fuel return lines or the open connections
satelettronica
on the injectors.
– Fit adapter C6 firmly onto return line connections of all 4 in‐

jectors.
– Connect hoses of return flow meter -VAS 6684- to adapters.
– Start engine and let it idle for several minutes.
Caution
Risk of damage to injectors after return lines have been pulled

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Installing fuel return lines

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Lubricate all seals with engine oil or assembly oil before installing.
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– Push return line connections carefully onto injectors. The

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– Check fuel system for leaks ⇒ page 263 .

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Danger of functional impairment due to contamination/soiling
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♦ Observe rules for cleanliness ⇒ page 7 .
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
return flow rate of the other injectors, that injector is probably de‐
fective.
– Clean all return line connections (e.g. with commercially avail‐
able cleaning solution) before removing.
– Dry all components after cleaning.
– Pull return line connections off injectors. To do this, press tabs
-1- and -2- down and simultaneously pull release pin upwards
-arrow-.
Note
Adhere strictly to rules of cleanliness. No dirt must be allowed to

get into the disconnected fuel return lines or the open connections
on the injectors.

– Detach electrical connector -arrow- from fuel pressure regu‐

lating valve - N276- .
Note
This prevents the fuel from being injected during the attempt at
starting.
– Fit adapter C6 firmly onto return line connections of all 4 in‐

jectors.
– Connect hoses of return flow meter -VAS 6684- to adapters.
– Activate starter 3 times, pausing for around 20 seconds after
each starting attempt to ensure that starter does not overheat.
• Return flow rate specification: 0 ml
– If fuel escapes from an injector, that injector has to be re‐
newed.
– Re-attach electrical connector from fuel pressure regulating
valve - N276- . n AG. Volkswagen A G do
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Push return line connections carefully onto injectors. The tee
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– Check fuel system for leaks ⇒ page 263 .
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– Delete event memory entry with an ⇒ Vehicle diagnostic test‐
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re-installed only on the same cylinders.
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♦ Observe rules for cleanliness when working on the injec‐
tion system.
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♦ The open connections must be sealed immediately with a
suitable cap.
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– Detach electrical connectors -arrows- from injectors.
Caution
When releasing high-pressure line, counterhold high-pressure

connection using an open-ended spanner. Leaks occur if high-
pressure connection is released.
– Unscrew union nuts of relevant high-pressure line -1 to 4- and

remove corresponding high-pressure line.
– Unscrew securing bolt of clamping piece -1- of injector which
is to be removed.
Note
In some vehicles (e.g. Touran), the plenum chamber bulkhead

must be removed ⇒ General body repairs, exterior; Rep. gr. 50 ;
Plenum chamber bulkhead; Assembly overview - plenum cham‐
ber bulkhead .

– Fit puller - T10055- with puller -T10415- and pull injector out
upwards using tapping movements.
Note
Pull injector out using rotary movements in order not to damage

sealing lip.
– Place the removed injectors on a clean cloth.

Important instructions for installing injectors
• Clean empty injector bores and sealing surfaces in cylinder
head using cleaning set - VAS 6811- before fitting injectors ⇒
Instructions
• When removing and installing, always renew the following
components and seals/O-rings: “copper seal”, “O-ring for in‐
jector bore”, “O-ring for injector return connection”.
• The following components and seals or O-rings must always
be renewed when an injector is renewed: “copper seal”, “O- AG. Volkswagen AG d
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♦ Check taper seat of respective high-pressure line for defor‐
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♦ The inside of the line must be free of deformations, constric‐
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If a used injector is being re-installed:
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– Spray tip of injector with a rust removal spray. Wait approx.
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– Renew seal for injector bore using assembly sleeve -

T10377- .
– To avoid damaging the O-ring, carefully slide the new, oiled
O-ring onto the fuel return connection.
– Install injectors.
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– Tighten union nuts of high-pressure lines hand-tight. Check lksw
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– Press return line connections carefully over seals and onto in‐
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♦ Write adaption of correction values for new injectors in engine
hole
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control unit ⇒ page 271 .
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♦ Reset learnt values of fuel pressure regulating valve - N276- .
♦ 01 - Engine electronics
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♦ 01 - Engine electronics functions
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♦ 01 - Reset adaptation values of engine ctrl. mod-

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– Allow engine to idle for a few minutes, then switch off engine
AG.
again.
– Switch off ignition.
– Check complete fuel system and return line connections (4
connections) for leaks ⇒ page 263 .
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
The return lines can be renewed only together with the non-return
valve as one unit.
– Road-test vehicle extensively. Accelerate with full throttle at

least once, and then check high-pressure section again for
leaks.
Note
clear event memory ⇒ Vehicle diagnostic tester . Then continue
with a road test.

3.7 Removing and installing high-pressure

lines
♦ Socket - T40055-
satelettronica
Caution
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Release rail and clamping pieces to more easily fit injection lksw
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lines free of tension. If necessary, shift rail slightlybyand turn
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This section describes how to install new injection lines. If previ‐

hole
spec
ously fitted injection lines are to be re-used, the points listed under
es, in part or in w
⇒ Item 9 (page 269) must be checked. Apart from that the pro‐
t to the co
cedure is identical.
rrectness of i
– If not already done, loosen securing bolts of rail so that it can

be moved.
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– If not already done, loosen securing bolts of clamping pieces

so they can be rotated.
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– Remove new high-pressure line from packaging. Remove

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– Initially hand-tighten high-pressure line union nuts “until seat‐

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– Remove injector lines from packaging. Remove sealing plug

and position line without laying it down anywhere again.
– First, hand-tighten union nuts of injection lines without a tool
“until resistance is encountered”.
– If necessary, proceed in the same way with other injection
lines.
– Tighten components in the specified sequence using socket -
T40055- ⇒ page 282 .
WARNING
The securing clamp for the high-pressure line between the

high-pressure pump and fuel rail (fuel rail) must always be in‐
stalled in the correct position. Otherwise fatigue failures or
stress ruptures may occur in the high-pressure line.
lkswage es n
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Installation position for the high-pressure line securing clamp
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– Tighten securing clamp to 8 Nm.

itte
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– Carefully press return line connections onto injector (check
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seal for damage). You should hear them click into place. Then,
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– Filling fuel system ⇒ page 262 .
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Tightening sequence Specified torque

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1. Securing bolt for clamping piece 8 Nm + turn 270° further

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2. High-pressure line between fuel rail and injector 28 Nm

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3.8 Removing and installing fuel rail


♦ Engine plug set - VAS 6122- AG. Volkswagen AG d

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– Detach electrical connector -arrow- from fuel pressure regu‐
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– Disconnect electrical connector -B- on fuel pressure sender -

G247- .
– Pull vacuum hose -A- from cylinder head cover.

– Remove fuel return hose from fuel rail; release hose clip
-arrow- to do so.
– Open retaining clips -arrows- of wiring harness and pull elec‐

trical connectors off at glow pin plugs.
satelettronica
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– Unscrew bolt -2- and union nuts -1 and 3-,lkandgen AG
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– Unscrew bolts -2-, lay coolant return line aside.

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– Unscrew bolts -arrows-, lay coolant return line aside.

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– Remove line guide from fuel rail and placeksto
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– Undo union nuts of 4 high-pressure lines -1-.
– Place the removed high-pressure lines on a clean cloth.
rrectness o
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– Remove fuel rail by unscrewing the two bolts -arrows-.
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Install in reverse order, noting the following: cted agen
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– Install high-pressure lines free of stress ⇒ page 281 .
Note
♦ Observe cylinder-specific markings if reusing high-pressure

lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer be used.

4-cylinder common
wage rail engine (2.0 l,dEA189
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⇒ “4.2 Removing and installing intake manifold”, page 287
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⇒ “4.3 Removing and installing throttle valve module”,
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4.1 Assembly overview - intake manifold
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1 - Guide tube
❑ for oil dipstick
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2 - Seal
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3 - Seal
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⇒ page 287
AG.
8 - Bracket
❑ For exhaust gas recircu‐
lation cooler change‐
over valve - N345- .
9 - 9 Nm
cooler changeover valve -
N345-
11 - Seal
❑ Renew
12 - 9 Nm
13 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
14 - Clip, 5 Nm
❑ Renew
15 - Connection
❑ For exhaust gas recirculation
16 - 8 Nm
17 - Seal
❑ Renew
18 - Throttle valve module - J338-
❑ With throttle valve potentiometer - G69-

19 - 8 Nm
20 - 9 Nm
21 - Clip
4.2 Removing and installing intake manifold

♦ Socket Torx T 30 - T10405-
satelettronica
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– Remove air intake hose. To do this, loosen hose clip -2-.

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4. Intake manifold 287


– Loosen hose clip -2- on throttle valve module - J338- , pull air
pipe off and leave in installation position.
– Disconnect electrical connectors at glow plugs ⇒ page 395 .
AG. Volkswagen AG d
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– Remove exhaust gas recirculation cooler changeover valve -
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N345- -left arrow- from bracket and lay aside.
spec
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– Unscrew bolts -2-, lay coolant return line aside.

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– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
line.
– Removing fuel rail ⇒ page 282 .
– Separate electrical connector -2- on throttle valve module -

J338- .
– Remove bolt -1- for dipstick guide tube.
– If a support is fitted between throttle valve module and crank‐
AG. Volkswagen AG d
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– Open and remove clamp -1-.

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– Unscrew bolts -arrows- for intake manifold diagonally from

outside to inside using socket T30 - T10405- .
– Carefully remove intake manifold.
Installing
⇒ “4.1 Assembly overview - intake manifold”, page 286 .
Note
Renew seals.
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– Tighten intake manifold bolts d from inside out in diagonal se‐
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- G31- and remove air pipe.
satelettronica
– Remove bolt -1- for dipstick guide tube.
– Unscrew bolts -arrows- and remove throttle valve module -
J338- . AG. Volkswagen A n G do
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es, in part or in w
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rrectness of i
l purpos
nform
mercia
at
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ion
c
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or
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ate
do
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for
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Cop py
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Prote AG.

5 Air filter
⇒ “5.1 Assembly overview - air filter housing”, page 292
⇒ “5.2 Removing and installing air filter housing”, page 293
5.1 Assembly overview - air filter housing
1 - Hose connection
2 - Air intake hose
❑ To turbocharger
❑ Check for soiling and
leaves.
3 - 1.5 Nm
❑ Qty. 2
4 - Air mass meter - G70-
⇒ page 304
satelettronica
5 - O-ring AG. Volkswagen AG d
agen oes
❑ Renew olksw not
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ara
❑ Install with silicone-free
rised
nte
lubricant. autho eo
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6 - 1.5 Nm
ce
le
un
pt
❑ For upper part of air fil‐

an
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ter.
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ab
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ility
7 - 8 Nm
ot
wit
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❑ For air filter lower part

h re
hole
spec
8 - Sleeve
es, in part or in w
t to the co
9 - Washer
10 - Air filter upper part
rrectness of i
❑ Remove dirt, leaves and

salt residues
l purpos
11 - Air filter element

nform
ercia
❑ Always use Genuine

Part for air filter element
m
a
com
ti
❑ Observe change inter‐

on in
vals ⇒ Maintenance ;
r
te o
thi
Booklet 808
s
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12 - Air filter lower part

um
fo
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❑ Remove dirt, leaves and salt residues

t.
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Cop py
❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
ht. rig
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❑ Country-specific version: With snow screen. co Vo
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Prote AG.
13 - Connection for water drain hose
❑ Cleaning
14 - Water drain hose
❑ Cleaning
15 - Flutter valve
❑ Cleaning and reinstalling.
16 - Intake air guide
❑ To lock carrier.

❑ Remove dirt, leaves and salt residues
17 - Spring-type clip
18 - Connection hose
❑ To turbocharger
5.2 Removing and installing air filter hous‐

ing agen
AG. Volkswagen AG d
oes
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Removing d byV gu
ara
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– Release retaining clips on sides -arrows- and pulluoff
th air duct
o eo
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cover. ss a c
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nl
pt
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spec
es, in part or in w
satelettronica
t to the co
– Release retaining clips on left and right -arrow A- and remove
rrectness of i
lower air duct -2-.
l purpos
– Detach lower air duct at mounting brackets -3-; swing lower air
duct backwards slightly for this.
nform
ercia
– Detach air pipe -1- from lower air duct -arrow B-.
m
at
om
i
– Detach electrical connector -1- from air mass meter - G70- and
on
c
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pull off hose -2-.
or
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ate
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5. Air filter 293

– Loosen hose clip -4- and remove air hose. wage

es n
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Vo
– Unscrew bolt -3- and remove air filter housing. d by ua
ran
ir se tee
o
Installing auth or
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⇒ “5.1 Assembly overview - air filter housing”, page 292 .
rm
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Note
hole
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es, in part or in w
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♦ Use a silicone-free lubricant to install the air hose.
rrectness of i
l purpos
nform
ercia
– Disconnect water drain hose -arrow- from lower part of air filter
m
and clean dirt and leaves from connection and hose.
a
com
ti
satelettronica
on in
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6 Senders and sensors

⇒ “6.1 Checking fuel pressure regulating valve”, page 295
⇒ “6.2 Removing and installing fuel pressure regulating valve”,
page 296
⇒ “6.3 Removing and installing fuel pressure sender”, page 298
⇒ “6.4 Removing and installing fuel temperature sender G81 ”,
page 301
⇒ “6.5 Removing and installing differential pressure sensor”, page
302
⇒ “6.6 Removing and installing air mass meter”, page 304
6.1 Checking fuel pressure regulating valve

♦ Engine plug set - VAS 6122-
satelettronica
AG. Volkswagen AG d
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♦ Measuring container, fuel-resistant spec

es, in part or in w
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WARNING
rrectness of i
♦ Read the rules on cleanliness for all work on the fuel sys‐
tem ⇒ page 7 .
l purpos

nform
mercia
at
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io

n
c
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or
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– Remove fuel return hose from fuel rail; release hose clip
at
do
riv
-arrow- for this.

p
cum
for
en
– Seal open fuel return hose using a bung from engine bung set
ng
t.
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- VAS 6122- . t. Cop py
rig
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Prote AG.
6. Senders and sensors 295

– Connect auxiliary hose -2- to fuel rail return connection -3-.

– Hold auxiliary hose in measuring container -4- to measure re‐
turn quantity.
– Start engine and run at idling speed for 30 seconds.
• Specified amount in 30 seconds: 90 to 110 ml
If the specification is not attained, the fuel pressure regulating
valve - N276- is defective.
6.2 Removing and installing fuel pressure
satelettronica
regulating valve
Fuel pressure regulating valve - N276- -2- is located in fuel rail. It
maintains constant pressure in fuel rail and injection lines (fuel
high-pressure circuit).
If the pressure in the fuel high-pressure circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
AG. Volkswagen AG d
Note agen oes
olksw not
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Fuel pressure regulating valve
horis
- N276- must be renewed each nte
eo
time after removing. aut ra
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cial p
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296
Prote AG.
Rep. gr.23 - Mixture preparation - injection
♦ Insert tool, 30 mm - T10553-
Removing
WARNING
♦ Observe rules for cleanliness and the instructions for

working on the fuel system ⇒ page 7 .
satelettronica
– Removing fuel rail ⇒ page 282 .

– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using commercial cold cleaning sol‐
ution etc. (no dirt must enter bore of fuel rail).
. Volkswagen AG
gen AG does
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Note y V olk not
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Do notautallow any cleaning agent to get into the connector, clean
ho eo
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it carefully.
ss c
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– Dry fuel pressure regulating valve - N276- .

itte
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– Loosen union nut while holding hexagonal flats on housing.

ility
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Then unscrew and remove by hand.

wit
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– Use suction device to extract dirt from fuel rail bore (threads
ole,
spec
and sealing surface). Do not use tools or other instruments for

this purpose.
t to the co
– Seal open fuel rail bore using a bung from engine bung set -
VAS 6122- .
rrectne
Installing
s
s o
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mer
atio
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n
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rig ht
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by lksw
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Prote AG.

Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Make sure that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are un‐
damaged.
♦ Check sealing surface at fuel rail bore.
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
ulating valve - N276- must be moistened with diesel.
– Tighten union nut by hand.

– Align new fuel pressure regulating valve so that connecting
line is free of tension after connector is attached.
– Hold regulating valve in this position with open-end spanner
on housing hexagon or use wrench (e.g. multi slip-joint grip‐
ping pliers).
satelettronica
– To tighten union nut, use insert AF 30 - T10553- .
– Installing fuel rail ⇒ page 282 . AG. Volkswagen AG d
agen oes
olksw not
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– After mounting, leave engine running iat sedmoderate
b speed for a ara
nte
few minutes and then switch off again.
hor eo
aut ra
s c
– Check fuel system for leaks. s
ce
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pt
– Read event memory ⇒ Vehicle diagnostic tester .
an
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spec
6.3 Removing and installing fuel pressure
es, in part or in w
t to the co
sender
Fuel pressure sender - G247- -item B- is located in fuel rail. It
rrectness of i
measures the current fuel pressure in the high-pressure system

and transmits a voltage signal to the engine control unit - J623- .
l purpos
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a
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tion in
r
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thi
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Cop py
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Removing
WARNING

satelettronica

– Before removal, clean thread area around fuel pressure send‐
er using, e.g., a commercially available cold cleaning solvent.
No dirt must enter bore. n AG. Volkswagen AG
wage does
Volks not
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Note oris nte
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th
au ra
c
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Do not allow any cleaning agent to get into the connector, clean
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nl
it carefully.
pt
du
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ab
– Dry fuel pressure sender - G247- .

ility
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– Detach electrical connector -item B- from fuel pressure sender

h re
- G247- .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
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ate
do
priv
cum
for
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ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew fuel pressure sender - G247- .

– Use suction device to extract dirt from fuel rail bore (threads
and sealing surface). Do not use tools or other instruments for
this purpose.
– Seal open fuel rail bore using a bung from engine bung set -
VAS 6122- .
Installing
Note
♦ Fuel pressure sender - G247- has a deformable sealing lip,

not a seal, for sealing purposes.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are undamaged. Re‐
using fuel pressure sender - G247- if possible if it has been
tested OK.
satelettronica
♦ Check sealing surface at fuel rail bore.
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
ulating valve - N276- must be moistened with diesel.
. Volkswag
AG en AG
agen does
olksw not
– Tighten fuel pressure sendered by V - G247- by hand. gu
ara
ris nte
o
– Then tighten fuel pressure
aut
h sender - G247- to specified torque. eo
ra
ss c
– After installing fuel pressure sender - G247- , allow engine to
ce
e
nl
pt
run at moderate speed for a few minutes to bleed fuel system.

du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
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hole
The high-pressure connections must “not” be opened for bleed‐

spec
ing; fuel system bleeds itself automatically.

es, in part or in w
t to the co
– Read out event memory and, if necessary, delete it ⇒ Vehicle

diagnostic tester .
rrectness of i

l purpos
– Carefully check entire fuel system for leaks.

nf
– Renew the affected component if leakage still occurs after

ercia
tightening to the correct torque.

rm
m
atio
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c

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emergency running mode during road test. Switch off engine and py by
co Vo
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Prote AG.

6.4 Removing and installing fuel tempera‐

ture sender - G81-
Removing
♦ Torque wrench - VAS 6854-
♦ Tool insert, 17 mm - T10395/3-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
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un
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an
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– Release and pull off electrical connector -1-.

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ab
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WARNING
wit
is n
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spec
The fuel line is under pressure.

t to the co
Fuel poses danger of injury to eyes and skin.

Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
rrectne
before loosening hose connections. Then reduce pressure by

carefully opening the connection.
ss o
cial p
f inform
– Unscrew fuel temperature sender - G81- .

mer
atio
m
– Collect escaping fuel with a cloth.

o
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c
i
or
Installing
thi
te
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pr
cum
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fo
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t.
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rig ht
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Prote AG.

– Renew oil seal -3-.

– Make sure that seal -2- is firmly seated.
– Screw fuel temperature sender - G81- into adapter -4-.
– Checking fuel system for leaks ⇒ page 263 .
Specified torque
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Component ir se
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Specified torque ran
o tee
h
Fuel temperature sender - G81- s aut
2 Nm or
ac
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nl
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6.5 Removing and installing differential
erm
ab
ility
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pressure sensor
wit
, is n
satelettronica
h re
hole
spec
Note
es, in part or in w
t to the co
Pressure differential sender - G505- determines charge status of
particulate filter. It can be connected via two lines before and after
rrectness of i
the particulate filter or with just one line before the particulate filter.
In this case the differential sender measures the ambient pres‐
l purpos
sure with an open line and calculates the differential pressure

from it.
nform
mercia
Removing at
om
ion
c
in t
r

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ate
do
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Prote AG.


wage es n
– Unscrew bolt -3-, pull off pressure yV
olksdifferential sender - G505- ot g
ua
from bracket -arrow-. ed b ran
oris tee
h
– Remove retaining clips aufrom both hoses.
t or
ac
ss
– Pull hoses carefully and straight from unions (unions break off
ce
e
nl
pt
pressure sensor very easily). du
an
itte
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erm
ab
Installing
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• Specified torque ⇒ page 344
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Before installing, blow out control lines of pressure differential
sender - G505- to particulate filter with compressed air to‐
l purpos
wards particulate filter (blocked or iced up due to condensa‐

tion).
nform
ercia
♦ Make sure that hoses are securely fitted and seal properly.
m
satelettronica
at
om
♦ If pressure hoses have been detached from particulate filter,
ion
c
tighten ⇒ page 344 .
in t
or
his
ate
do
riv
An adaptation must be performed after renewing pressure differ‐

p
cum
or
ential sender - G505- and/or particulate filter. (The procedure is

f
en
ng
t.
also described under Guided Functions).
yi Co
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Select correct vehicle in Guided fault finding. rig ht
py by
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by lksw
– Press “GoTo” button. Prote
cted AG.
agen
– Press “Function/component selection”.

– Select “drive (Rep. Gr. 01; 10 - 39)”.
– Select respective engine code.
– “01 - Self-diagnosis compatible systems”
– Select “01 - Diesel direct injection and glow plug system
EDC 17”.
– Select “01 - Functions”.
– Select “01 - Reset programmed values of pressure differential
sender (PDS)”.

6.6 Removing and installing air mass meter

Removing
– Remove upper part of air filter ⇒ page 292 .
– Carefully pull air mass meter - G70- out of guide on air filter
housing.
Installing
⇒ “5.1 Assembly overview - air filter housing”, page 292 .
To ensure the proper function of the air mass meter - G70- it is
important to adhere to the following work sequences.
Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the air mass meter and falsify the measured
air mass value. This would lead to loss of power, since a
satelettronica
smaller injection quantity is calculated.
♦ Use genuine air filter element.
♦ Always renew seal if damaged (infiltrating air).
♦ Use a silicone-free lubricant to install the air hose and seal.
♦ Secure hose connections with hose clips in such a wayAthat
G. Volkswagen
lksw
agen AG do
es n
ot g
o
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edb ran
– Check for salt residue, dirt and leaves tin ris
ho air mass meter and tee
or
air hose (clean air side). au ac
ss
ce
e
– Check intake duct for contamination up to air filter element. If

nl
pt
du
contamination is found, remove salt residue, dirt and debris

an
itte
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from top and bottom part of air filter housing by flushing it out
erm
ab
or using a vacuum cleaner if necessary.

ility
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, is n
– Install upper part of air filter ⇒ page 292 .

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7 High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 305
⇒ “7.2 Removing and installing high-pressure pump”, page 306
7.1 Assembly overview - high-pressure pump
⇒ page 69
❑ Renew
3 - Hub
❑ Use counter-hold tool g-en AG
. Volkswagen AG
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T10051- to looseny V and
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❑ To remove,aut
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use puller - ra
T40064-
ss . c
satelettronica
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un
pt
4 - High-pressure pump tooth‐
an
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5 - 20 Nm
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6 - 95 Nm
h re
ole,
spec
t to the co
❑ Renew
rrectne
❑ With fuel metering valve

- N290- (do not open)
s
❑ After renewing, initial

s o
fuel filling must be car‐

cial p
f in
ried out (never allow

form
mer
pump to run dry)

atio
⇒ page 262 .
om
n
c

or
n thi
e
⇒ page 306
t
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9 - Fuel supply hose

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10 - Fuel return hose
Co
Cop py
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11 - High-pressure lines,
rig ht
py by
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28 Nm by c lksw
cted agen
Prote AG.
❑ Between high-pressure pump and fuel rail
❑ Do not interchange
Note

ings if reusing high-pressure
lines.
checks:
tion and cracks.
7. High-pressure pump 305

♦ The inside of the line must be

free of deformations, constric‐
tions and damage.
be used.
❑ Install so that component is not under tension
7.2 Removing and installing high-pressure

lksw
agen
AG. Volkpump
swagen AG
does
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Special tools and workshop ut
ho or
ac
equipment required ss
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es, in part or in w
satelettronica
t to the co
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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t.
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Cop py
t. rig
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by
cted agen
Prote AG.

♦ Puller - T40064- with T40064/1

Removing
Caution
♦ Observe rules for cleanliness and the instructions for

working on the fuel system ⇒ page 7 .
Risk of irreparable damage to high-pressure pump if allowed
to run dry.
while empty. Initial fuel filling ⇒ page 262 .
– Remove toothed belt from camshaft and high-pressure pump

⇒ page 133
– Unscrew bolts -2-, remove toothed belt sprocket from high-
pressure pump.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
ut ra
– Unscrew nut -1- on hub of shigh-pressure
s a pump; counterhold c
with counter-hold tool - T10051- for this.
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Position puller - T40064- with thrust piece - T40064/1- and pin

- T40064/2- as shown and pull hub off high-pressure pump.
nform
ercia
Counterhold with an 24 mm open-end spanner.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

AG. Volkswagen
CC 2010 ➤ , Eoslk2006
swa ➤ , Golf 2009 ➤ d,oGolf
gen AG
es n Plus 2009 ➤ , Passat 2011 ...
Vo ot g
4-cylinder common
db
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– Unscrew bolts
au -2-, lay coolant return line aside. ra
c
ss
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un
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pe
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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satelettronica
um
fo
en
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t.
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Cop py
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cted agen
Prote AG.
– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
line.
– Separate electrical connectors -1- and -3-.

Vehicles with high-pressure pump support

– Unscrew nuts -1- and bolt -2- from the support -A-.
– Remove fuel supply hose -2- and return hose -4-.
– Unscrew bolts -arrows- for high-pressure pump.

– Carefully remove high-pressure pump.
Installing
– Gently set high pressure pump in place and tighten bolts
-arrow-.
satelettronica
⇒ “7.1 Assembly overview - high-pressure pump”, page 305
Vehicles with high-pressure pump support
– If necessary, fit hex centre studs for support in the high-pres‐
sure pump. Specified torque: 15 Nm.
olkswagen AG
en AG. V
– Apply support, tighten nuts -1- and bolt -2- on support by
olkshand.
wag does
not
It should be possible to move the support. ed
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– First tighten bolt -2- and then nuts -1-. Specified
auth torque: 23 Nm. eo
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ss c
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nl
pt
du
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erm
ab
– Install high-pressure lines ⇒ page 281 .
ility
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wit
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Caution
hole
spec
es, in part or in w
Risk of irreparable damage to high-pressure pump if allowed t to the co

to run dry.
rrectness of i

while empty. Initial fuel filling ⇒ page 262 .
l purpos
nf
ercia
orm
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Cop py
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8 Lambda probe
⇒ “8.1 Removing and installing Lambda probe”, page 310
8.1 Removing and installing Lambda probe

♦ Lambda probe open ring spanner set - 3337-
AG. Volkswagen AG d
agen oes
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satelettronica
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Removing ss
ce
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un
pt
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d
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rm
ab
– Disconnect electrical connector -arrow- for Lambda probe -
pe
ility
G39- .
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Unscrew Lambda probe - G39- -3-, using tool from Lambda

probe open ring spanner set - 3337- .
nform
ercia
Installing
m
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tion in

r
te o
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• Specified torque: 50 Nm
s
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Note
Co
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♦ Threads of new Lambda probes are already coated with as‐
p by
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sembly paste; the paste must not get into the slots on the probe cted agen
Prote AG.
body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. Do not allow any paste to enter
the slots on the probe body. High-temperature paste ⇒ Elec‐
tronic Parts Catalogue .
♦ When installing, the Lambda probe's electrical wiring connec‐
tion must always be re-attached in the same locations to
prevent the Lambda probe cable from coming into contact with
the exhaust pipe.

9 Engine control unit

⇒ “9.1 Removing and installing engine control unit”, page 311
⇒ “9.2 Removing and installing engine control unit with protective
housing”, page 318
9.1 Removing and installingVoengine
lksw
age control es n
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unit
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⇒ “9.1.1 Removing and installingssengine
a control unit J623 , Golf, ac
Scirocco”, page 311
ce
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nl
pt
du
an
⇒ “9.1.2 Removing and installing engine control unit J623 , Golf
itte
y li
Plus, Touran”, page 312
erm
ab
ility
ot p
⇒ “9.1.4 Removing and installing engine control unit J623 , Ti‐
wit
, is n
guan”, page 314
h re
hole
spec
⇒ “9.1.3 Adapting functions and components, Eos”, page 313
es, in part or in w
t to the co
⇒ “9.1.5 Removing and installing engine control unit J623 , Eos”,
page 315
satelettronica
⇒ “9.1.6 Removing and installing engine control unit J623 , Passat
rrectness of i
and CC up to 10.2010”, page 316
l purpos
⇒ “9.1.7 Removing and installing engine control unit J623 , CC

from 11.2010”, page 317
nf
ercia
o
9.1.1 Removing and installing engine control
rm
m
atio
m
unit - J623- , Golf, Scirocco

o
n in
or c
thi
e
If the engine control unit is to be renewed, connect the ⇒ Vehicle

t
sd
iva
diagnostic tester and carry out the guided function “Renewing
o
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rp
cu
control unit”.
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Removing Cop py
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rig ht
– Switch off ignition. py by
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cted agen
– Remove windscreen wiper arms: ⇒ Electrical system; Rep. Prote AG.
head .
– Push retaining frame in -direction of arrow- and remove engine
control unit.
9. Engine control unit 311

– Push locking devices of connectors in -direction of arrow- and

pull off connectors.
Installing
– Fit connectors to engine control unit and slide locking devices

onto stop in -direction of arrow-.
AG. Volkswagen AG d
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olksw not
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or eo
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un
pt
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rm
ab
pe
ility
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– Place engine control unit into retaining frame and push up‐
hole
spec
wards in direction of -arrow-.
es, in part or in w
t to the co
– Install plenum chamber bulkhead ⇒ General body repairs,
head .
rrectness of i
– Wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
l purpos
wiper system; Removing and installing wiper arms .
nform
mercia
a
com
tion in
r
te o
thi
s
iva

do
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rp
cum
unit - J623- , Golf Plus, Touran

fo
en
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t.
yi Co
Cop py
t. rig
gh ht
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Note
p by
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by c lksw
cted agen
Prote AG.
If the engine control unit is to be replaced, connect the vehicle
engine control unit”.
Removing engine control unit

head .

– Loosen securing nuts -arrows-.

– Release connector from engine control unit and detach.
– Slide retaining plate -1- off engine control unit.

Installing engine control unit
– Push retaining plate onto engine control unit.
satelettronica
. Volkswagen AG
gen AG d
– Tighten securing
Vol
knuts
swa -arrows- to 10 Nm.oes no
t
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– Attach and
or lock connectors.
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– Install
ss plenum chamber bulkhead ⇒ General
a body repairs,c
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un
pt
head .
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9.1.3 Adapting functions and components,

rrectne
Eos
s

s o
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♦ Vehicle diagnostic tester

form
mer
Procedure
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– Connect vehicle diagnostic tester .

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Select “Guided Fault Finding” on vehicle diagnostic tester .

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When all control units have been read:

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– Select “Function/component selection”.
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– Select “Drive”.
AG.
– Select “Engine code”.

– Select “01 - Systems capable of self-diagnosis”.
– Select “engine control”.
– Select “Functions”.

– Select “Function or component”.

unit - J623- , Tiguan
Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
satelettronica
– Remove retaining frame with engine control unit from plenum
chamber. gen AG
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– Press catches -1- outwards and slide engine control unit -2- in
wit
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-direction of arrow-.
h re
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spec
Installing
t to the co
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cial p
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– Slide engine control unit -1- in -direction of arrow- into retaining

i
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– Place retaining frame with engine control unit on bracket -4-.

um
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Specified torque of securing nuts for retainer -4-: 6 Nm.
yi Co
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rig ht
py by
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– Tighten securing bolts -3- to 7 Nm.

– Attach connectorsgeto
n Aengine
G. Volkswcontrol
agen AG unit and slide catches
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– Attach
or connector -1- to heated windscreen control
ise an
teeunit - J505- .
h
ut or
– Install
ss
a
plenum chamber cover ⇒ General body repairs,
ac
exte‐
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
ce
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un
pt
installing plenum chamber cover .
an
d
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pe
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unit - J623- , Eos
rrectness of i
Note
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nform
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satelettronica
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Removing
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chamber cover .
ht ht
rig by
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AG.

head .
– Release and detach front connector -1- from engine control
unit.
– Lever up catch -2- slightly.
– Slide engine control unit out of bracket -arrow-.
– Release and detach rear connector from engine control unit.
Installing
– Connect and lock rear connector to engine control unit.
– Push engine control unit onto retaining plate.
– Connect and lock front connector to engine control unit.
– Install plenum chamber cover ⇒ General body repairs, exte‐
head .


unit - J623- , Passat and CC up to
10.2010
Removing
chamber cover .
– Pull connector (if there is one) -1- off heated windscreen con‐
trol unit - J505- .
satelettronica
– Remove securing bolts -3-.
– Remove retaining frame with engine control unit from plenum
chamber. AG. Volkswagen n AG do
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– Press catches -1- outwards and slide engine control unit -2- in wit
, is n
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hole
Installing
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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io

n
c
in t
or
frame.
his
ate
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– Place retaining frame with engine control unit on bracket -4-.

p
cum
for
en
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Specified torque of securing nuts for retainer -4-: 6 Nm.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tighten securing bolts -3- to 7 Nm.

– Attach connectors to engine control unit and slide catches
-2- inwards.
– Attach connector -1- for heated windscreen control unit -
J505- .

unit - J623- , CC from 11.2010
If engine control unit is to be replaced, connect ⇒ Vehicle diag‐
nostic tester and carry out “Renew control unit” guided function.
Removing
satelettronica
chamber cover .
exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - obulk‐
. V lkswagen AG
head . swa
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– Push down retaining frame in directioned of -arrow- and remove
by ara
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engine control unit. oris eo
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pt
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ab
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es, in part or in w
t to the co
rrectness of i

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Installing
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– Place engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
head .
– Fit windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wind‐
screen wiper arms .
satelettronica
AG. Volkswagen AG d
agen oes
ksw
9.2 Removing and installing engine control d by Vol not
gu
ara
unit with protective housing uthorise nte
eo
ra
s a c
⇒ “9.2.1 Removing and installing engine control unit J623 with s
ce
le
protective housing, Golf, Scirocco”, page 318

un
pt
an
d
itte
y li
⇒ “9.2.2 Removing and installing engine control unit J623 with
rm
ab
protective housing, Golf Plus, Touran”, page 321
pe
ility
ot
wit
, is n

protective housing, Tiguan”, page 323 h re
hole
spec
es, in part or in w

t to the co
protective housing, Eos”, page 324
protective housing, Passat and CC up to 10.2010”, page 327
rrectness of i

l purpos
protective housing, CC from 11.2010”, page 328

nform
ercia

unit - J623- with protective housing,
m
a
com
tio
Golf, Scirocco
n in
r
te o
thi
s
iva
If the engine control unit is to be replaced, connect ⇒ Vehicle di‐

do
r
rp
agnostic tester and carry out “Renew control unit” guided function.
um
fo
en
ng
t.
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Removing
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr. cted agen
Prote AG.
92 ; Windscreen wiper system; Removing and installing wind‐
screen wiper arms
head .

– Push retaining frame down in -direction of arrow- and remove

engine control unit.
– Unscrew shear-head bolts -arrows- using a pair ofwpliers.

agen
AG. Volkswagen AG d
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Vol t gu
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satelettronica
ility
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spec
t to the co
– Insert screwdriver between both locking plates -arrow-.
rrectne
– Carefully press screwdriver in -direction of arrow- and bend
retaining bar -1- upwards at the same time.
ss o
cial p
f inform
mer
atio
om
n
c
i
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n thi
te
sd
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t.
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Cop py
– Bend retaining bar -1- in direction of -arrow- until it can be
t. rig
gh ht
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pulled off connector. p by
co Vo
by lksw
cted agen
Prote AG.


Installing

satelettronica
– Fit retaining bar -1- onto connectors and press it in direction
of -arrow-.
– Guide pin -2- to stop into hole
agen
Aon
G. Vvalve
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gen AG housing.
do w es n
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ab
ility
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wit
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spec
– Use new shear-head bolts to secure retaining bar onto engine

es, in part or in w
control unit -arrows-.

t to the co
– Evenly tighten shear-head bolts until bolt heads shear off

-arrows-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Locate engine control unit in retaining frame and push up‐

wards in -direction of arrow-.

. Volkswagen AG
head . swa
gen AG does
k not
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– Wiper arms ⇒ Electrical system; Rep. gr. d b92 ; Windscreen ara
ise nte
wiper system; Removing and installing
th wiper arms .
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au ra
c
ss
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
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unit - J623- with protective housing, Golf
hole
spec
es, in part or in w
Plus, Touran
t to the co
rrectness of i
♦ Grip pliers
satelettronica
l purpos
♦ Hot air blower from wiring harness repair set - VAS 1978-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ If the engine control unit is to be renewed, connect the vehicle

diagnosis, testing and information system - VAS 5051B- and
carry out the guided function “Renewing engine control unit”.
♦ The shear-head bolt threads are coated with locking com‐
pound. Heating the shear-head bolt with a hot air blower
releases the locking effect of the locking compound.
Removing:
head .
Caution
Cover lines, cables, connections and control units in the vicinity

of the engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn potentiometer for temperature adjustment -2- to maxi‐

mum heater output (600 °C).
– Set two-stage switch for air quantity -3- to position 3. olkswagen AG
en AG. V ag does
ol ksw not
– Move nozzle of hot air blower towards bshear-head
yV bolt. gu
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– Switch hot air blower on and heat
ut
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ss c
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WARNING un
pt
an
d
itte
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erm
When shear-head bolts are heated up, parts of the protective
ab
ility
housing will be subjected to a large amount of heat. Wear pro‐
ot p
wit
tective gloves to avoid injury.
is n
h re
ole,
spec
t to the co
– Unscrew shear-head bolts -arrows- using a pair of pliers and
remove cover of protective housing.
rrectness o
cial p
satelettronica
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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– Then loosen securing nuts -arrows- of control unit bracket.
Co
Cop py
ht. rig
– Release connector from engine control unit and pull off. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press catches -1- and -2- outwards. Pull engine control unit
off control unit bracket in direction of arrow.
Installing:
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Connect connector to engine control unit and lock.

– Tighten securing bolts -arrows- to 10 Nm.

– Fit cover of protective housing.
– Evenly tighten new shear-head bolts -arrows- until bolt heads

shear off.
head .
satelettronica
unit - J623- with protective housing, Ti‐
guan . Volkswag AG en AG
agen do
If the engine control unity Visolkto
swbe replaced, connect the
es n
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diagnostic tester and isedcarry
b out the guided function “Renewing ara
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Special tools and
s workshop equipment required
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♦ Grip pliers
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ab
Removing
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wit
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– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.

spec

es, in part or in w
screen wiper arms

t to the co

rrectness of i
chamber cover .
l purpos
– Unscrew bolts -1-.

– Cover plenum chamber with clean cloth to prevent it from be‐
nform
ercia
ing scratched.
m
at
om
– Raise engine control unit plus retaining frame slightly.

ion
c
in t
or
– Release engine control unit in -direction of arrow- and pull

his
ate
slightly out.
do
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for
en
ng
t.
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Cop py
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– Bend upwardly projecting ends -1- of locking bar outwards.
pt
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– Unscrew shear-head bolts -2- using a pair of pliers and remove
erm
ab
locking bar.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
at
om
i
– Remove engine control unit.
on
c
in t
or
Installing:
his
ate
do
priv
cum
for
en
ng
t.
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satelettronica
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

frame until it engages.
– Bolt retaining frame in place.
Specified torque: 6 Nm

-1- inwards.
– Fit new locking bar and tighten new shear-head bolts until
heads shear off.

unit - J623- with protective housing, Eos
♦ Electric cutter - V.A.G 1561 A-
♦ Saw set - V.A.G 1561/14-

♦ Grip pliers
♦ Hot air blower from wiring harness repair set - VAS 1978-
satelettronica
Removing
Note
agen
AG. Volkswagen AG d
oes
olksw not
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If the engine control ris unit is to be replaced, connect the vehicle
ed
nte
diagnostic tester ut and carry out the guided function “Renewing or a
ho e
engine controls unit”.
s a c
ce
e
nl
pt
du
an

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ab

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wit
, is n

h re
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spec

es, in part or in w

t to the co
chamber cover .
rrectness of i

head .
l purpos
Note
nform
mercia
at
The shear-head bolt threads are coated with locking compound.

om
ion
Heating the shear-head bolt with a hot air blower releases the
c
in t
or
locking effect of the locking compound.

his
ate
do
priv
cum
for
en
ng
Caution
t.
yi Co
Cop py
ht. rig
ht
Cover lines, cables, connections and control units in the vicinity
rig by
opy Vo
of the engine control unit to prevent damage through heat.
by c lksw
cted agen
Prote AG.

Perform settings on hot air blower -4- as shown:

– Turn potentiometer for temperature adjustment -2- to maxi‐
mum heater output (600 °C).
– Set two-stage switch for air quantity -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid injury.
– Move nozzle of hot air blower towards shear-head bolt.

– Switch hot air blower on and heat bolts.
– Unscrew bolts using grip pliers .
Note
satelettronica
If the bolts cannot be unscrewed, saw into the heads of the shear-
head bolts so that 2 parallel slots are created -arrows-. Then
unscrew.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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– Insert screwdriver -A- between protective housing and retain‐

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to side from retaining plate -arrow-.

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– Release and detach front connector -1- from engine control

unit.
– Lever up catch -2- slightly.
– Then push engine control unit out of retainer -arrow-.
– Release and detach rear connector from engine control unit.
Installing
– Connect and lock rear connector to engine control unit.
– Push engine control unit onto retaining plate.
– Connect and lock front connector to engine control unit.
– Push protective housing onto retaining plate.
– Evenly tighten shear-head bolts -1- until bolt heads shear off.
satelettronica
head .

unit - J623- with protective housing, agen
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If the engine control unit is to be replaced, connect
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locking bar.
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– Remove engine control unit.

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frame until it engages.
– Bolt retaining frame in place.

-1- inwards.
– Take a new locking bar and tighten new shear-head bolts until
heads shear off.

unit - J623- with protective housing, CC
from 11.2010
If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
agnostic tester and carry out “Renew control unit” guided function.

Removing
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
screen wiper arms
head .
– Push down retaining frame in direction of -arrow- and remove
engine control unit.
AG. Volkswagen AG d
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t to the co
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– Bend retaining bar -1- in direction of -arrow- until it can be

pulled off connector.

Installing
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– Fit connectors to engines acontrol unit and push locking devices
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– Fit retaining bar -1- onto connectors and press it in direction

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nform
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– Guide pin -2- to stop into hole on valve timing housing.

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– Place engine control unit into retaining frame and push retain‐
t to the co
ing frame upwards in direction of -arrow-.
rrectne
head .
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inform
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26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 332
⇒ “1.2 Aligning exhaust system free of stress”, page 341
⇒ “1.3 Installation position of clamp”, page 342
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencers, Tiguan”, page 332
⇒ “1.1.2 Assembly overview - silencers, vehicles with front-wheel
drive, Golf, Golf Plus, Eos, Scirocco”, page 333
⇒ “1.1.3 Assembly overview - silencer, vehicles with four-wheel
drive, Golf”, page 334
. Volkswagen AG
gen AG does
⇒ “1.1.4 Assembly overview - silencers; vehicles withVol
kSCR
swa sys‐ not
tem”, page 336 ed
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satelettronica
⇒ “1.1.5 Assembly overview - silencers, vehicles
auth with front-wheel eo
ra
drive, Passat and CC with engine codes sCFFA, CFFB, CFGB,
s c
CFGC”, page 336
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un
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⇒ “1.1.6 Assembly overview - silencers, vehicles with front-wheel
y li
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drive, Passat and CC with engine code CLLA”, page 337
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⇒ “1.1.7 Assembly overview - silencers, vehicles with four-wheel
is n
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drive, Passat and CC with engine code CFGB, CFGC”,
ole,
page 338
spec
t to the co
⇒ “1.1.8 Assembly overview - silencers, Touran”, page 340
⇒ “1.1.9 Assembly overview - silencers, vehicles with four-wheel
drive, Passat and CC with engine codes CFFA, CFFB”,
rrectne
page 341
1.1.1 Assembly overview - silencers, Tiguan

ss o
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f inform
mer
Note
atio
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n
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i
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♦ Removing and installing exhaust manifold ⇒ page 243 .

thi
te
sd
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♦ After working on the exhaust system, ensure that the system

i
o
pr
cum
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is not under stress and that there is sufficient clearance to the

fo
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bodywork. If necessary, loosen clamping sleeve and align si‐

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332 Rep. gr.26 - Exhaust system

1 - 25 Nm
2 - Exhaust pipe
3 - Rear silencer
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 341 .
4 - Mounting
❑ With retaining ring
❑ Renew if damaged
5 - 25 Nm
6 - Mounting
7 - Tunnel cross-piece
8 - Not assigned in illustration
9 - Clamping sleeve agen
AG. Volkswagen AG d
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❑ Installation position and by V o gu
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ara
specified torque rise
d
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⇒ page 342 autho eo
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1.1.2 Assembly overview - silencers, vehicles

m
with front-wheel drive, Golf, Golf Plus,

com
tion in
Eos, Scirocco
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Mounting position and specified torque of the clamping sleeve

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⇒ page 342
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1. Exhaust pipes and silencers 333

1 - 25 Nm
❑ Renew
2 - Retaining ring
3 - Rear silencer
4 - Rear mounting
5 - 25 Nm
6 - Tunnel cross-piece
7 - Front mounting
satelettronica
AG. Volkswagen AG d
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1.1.3 Assembly overview - silencer, vehicles

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with four-wheel drive, Golf

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Mounting position and specified torque of the clamping sleeve

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⇒ page 342
spec
es, in part or in w
t to the co
rrectness of i
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AG. Volkswagen AG d
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CC 2010
thor ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus e o2009 ➤ , Passat 2011 ...
u ra
ss a 4-cylinder common rail engine (2.0 l, EA189 Gen
c II) - Edition 06.2019
ce
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nl
pt
du
1 - Front mounting
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itte
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2 - Retaining ring
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3 - 25 Nm hole
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4 - Rear mounting
t to the co
5 - Rear silencer
rrectness of i
l purpos
nform
mercia
at
om
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1.1.4 Assembly overview - silencers; vehicles with SCR system
1 - From reducing agent cata‐

lytic converter
2 - Clamping sleeve
❑ Before tightening, align
cold exhaust system
free of tension
⇒ page 341
❑ Tighten bolted connec‐
tions evenly.
❑ Specified torque
⇒ page 342
3 - Mounting
4 - 25 Nm
❑ Renew
5 - Exhaust pipe
satelettronica
6 - Clamping sleeve
cold exhaust system
free of tension
⇒ page 341
tions evenly. AG. Volkswagen AG d
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⇒ page 342 byV gu
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8 - Rear silencer
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with front-wheel drive, Passat and CC
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with engine codes CFFA, CFFB, CFGB,

l purpos
CFGC
nform
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Note
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tion in
♦ Mounting position and specified torque of the clamping sleeve

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⇒ page 342
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1 - Clamping sleeve
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⇒ page 341
tions evenly.
⇒ page 342
2 - Retainer
3 - Centre mounting
4 - 25 Nm
❑ Renew
5 - Rear mounting
6 - Rear silencer
satelettronica
AG. Volkswagen AG d
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Note
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⇒ page 342
nform
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AG. VolkGen
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1 - Clamping sleeve ed
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❑ Before tightening, alignutho
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⇒ page 341
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⇒ page 342
ole,
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2 - Retaining ring
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3 - Centre mounting
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4 - 25 Nm
ss o
❑ Renew
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5 - Rear silencer
mer
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6 - Front silencer
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with four-wheel drive, Passat and CC
with engine code CFGB, CFGC
Note

⇒ page 342
loaded.

1 - Clamping sleeve
cold exhaust system
free of tension
⇒ page 341
tions evenly.
❑ Specified torque AG. Volkswagen AG d
⇒ page 342 agen oes
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7 - Front silencer
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1.1.8 Assembly overview - silencers, Touran
Note

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♦ After working on the exhaust system, ensure
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a d
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clearance to the bodywork. If necessary,
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ise
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5 - Rear tunnel cross-piece
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6 - Mounting
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with four-wheel drive, Passat and CC
with engine codes CFFA, CFFB
Note

⇒ page 342
loaded.
♦ Renew self-locking nuts.wagen AG. Volkswagen AG doe
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1- Clamping sleeve
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du
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⇒ page 341
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⇒ page 342 t to the co

2 - Retaining ring
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3 - Front mounting
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4 - 25 Nm
nform
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❑ Renew
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5 - Centre mounting
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❑ Renew if damaged ht. rig
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8 - Securing bolt by c lksw
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❑ Specified torque ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 42 ; Rear
axle; Overview - rear
axle .
9 - Front silencer
1.2 Aligning exhaust system free of stress

• Engine must be cold

– Loosen bolts -3 and 4- on front clamp -1-.

– Align front clamp -1- to marking -A- on front exhaust pipe -2-
(-arrow- points forwards).
• Dimension -a- = ⇒ page 342
• Do not allow the bolts must be on the right and the ends to
protrude beyond the lower edge of the clamp.
– Push rear silencer forwards into clamp until dimension -a-

15…17 mm is attained between mountings for body and rear
silencer. -Arrow- points in direction
agen
AG.of
Votravel.
lkswagen AG
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olks ot g
– Align rear silencer horizontally.
db
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– Tighten clamp boltstho in this position. Mounting position and e or a
au
specified torque
ss ⇒ page 342 . c
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1.3 Installation position of clamp t to the co
Note
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Gradual introduction of clamp with continuous clip.

ss o
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Specified torque and mounting dimensions of clamping sleeve.

form
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Clamp -A- with 2 individual clips.

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Specified torque: 35 Nm C py
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Installation dimension -a- for vehicles with marking on front ex‐

haust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
a - Installation dimension
A - Marking

Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right
Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces to rear.
satelettronica
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 ➤ , Golf Plus 2009 ➤ , Passat
. Volkswa2011
gen AG...
gen AG does
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4-cylinder common rail engine (2.0 l, EA189 Gen II)Vo-lkEdition 06.2019 not
g y ua
db ran
rise tee
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2 Emission control ss au ac
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pt
⇒ “2.1 Assembly overview - emission control”, page 344
an
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⇒ “2.3 Removing and installing catalytic converter”, page 354
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2.1 Assembly overview - emission control
hole
spec
es, in part or in w
⇒ “2.1.1 Assembly overview - front exhaust pipe with particulate
t to the co
filter”, page 344
⇒ “2.1.2 Assembly overview - front exhaust pipe with catalytic
rrectness of i
converter, engine codes CLCA, CLLA, CLJA”, page 346
l purpos
2.1.1 Assembly overview - front exhaust pipe

with particulate filter
nform
mercia
a
com
tio
Note
n in
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te o
thi
s
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satelettronica
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bodywork. If necessary, loosen clamping sleeve and align si‐ t. C rig
gh ht
lencer and exhaust end pipe so that sufficient clearance is pyri by
Vo
co
maintained to the bodywork and the support rings are evenly
by lksw
cted agen
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loaded.
AG.

♦ The decoupling element of the front exhaust pipe must be se‐
cured with transportation lock - T10404- to stop overstretch‐
ing.

♦ Transport lock - T10404-

Note
If particulate filter or pressure differential sender - G505- is re‐

newed, pressure differential sender - G505- must be adapted
using vehicle diagnostic tester as a matter of priority: Guided
Functions; Adapting pressure differential sender - G505- .
1 - Pressure differential sender

- G505-
⇒ page 302
2 - 10 Nm
3 - Shield
4 - Lambda probe - G39-
❑ 50 Nm
❑ Grease only the thread
with high-temperature
satelettronica
paste - G 052 112 A3- .
Do not allow high-tem‐
perature paste - G 052 n AG. Volkswagen AG do
112 A3- to get into slots lkswage es n
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❑ Removing and installing utho tee
or
⇒ page 310 ss
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5 - Exhaust gas temperature

un
pt
an
d
sender 4 - G648-
itte
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rm
❑ 60 Nm ab
pe
ility
ot
❑ Thread of sender is wit

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coated.
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spec

es, in part or in w
grease.
t to the co
6 - Seal
❑ Renew
rrectness of i

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sition
7 - Clip
nform
ercia
❑ Renew
m
❑ 7 Nm
com
tion in

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sender 3 - G495-
s
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❑ 60 Nm
um
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❑ Thread of sender is coated.

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❑ Do not additionally oil or grease. t. C rig
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9 - 25 Nm
co Vo
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Prote AG.
10 - Mounting
11 - Particulate filter
❑ With oxidation catalytic converter and front exhaust pipe.
❑ After renewing, the adaption of ash mass comparison must be set to zero with the vehicle diagnostic
tester under “Guided functions”.
2. Emission control 345

12 - 25 Nm
. Volkswagen AG
gen AG does
13 - Bracket Vol
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not
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❑ Bolted to cylinder
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14 - Control line,s45
au Nm ra
c
s
❑ If not fitted, seal with dummy plugs.
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15 - Bracket
itte
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❑ Bolted to diesel particulate filter
ility
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16 - Clip
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❑ Renew
spec
es, in part or in w
17 - Bracket
t to the co
❑ Bolted to cylinder head.
18 - 25 Nm
rrectness of i
19 - 8 Nm
l purpos
20 - 25 Nm
nform
ercia
satelettronica
m
at
om
2.1.2 Assembly overview - front exhaust pipe
ion
c
in t
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with catalytic converter, engine codes

o
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ate
CLCA, CLLA, CLJA do

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for
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Note t. C rig
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♦ After working on the exhaust system, ensure that the system Prote
cted AG.
agen
bodywork.
♦ If necessary, loosen double and single clamps and align si‐
lencers and exhaust pipes so that sufficient clearance is main‐
tained to the body everywhere and the mountings are evenly
loaded.
♦ Removing and installing exhaust manifold with turbocharger
⇒ page 243 .
♦ Do not bend the flexible joint in the front exhaust pipe by more
than 10° because it might otherwise be damaged. Secure with
transportation lock - T10404- .
♦ Renew seals, gaskets and self-locking nuts.

1 - Catalytic converter
⇒ page 354
2 - Seal
❑ Renew
sition
3 - Clip
AG. Volkswagen AG d
❑ 7 Nm agen oes
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4 - 25 Nm orise nte
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5 - 25 Nm ss a c
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6 - Bracket
pt
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❑ Bolted to crankcase
y li
erm
ab
ility
7 - Bracket
ot p
wit
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❑ Bolted to cylinder head.
h re
hole
spec
8 - 25 Nm
es, in part or in w
satelettronica
t to the co
9 - 25 Nm
rrectness of i
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nf
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2.2 Removing and installing particulate filter
agen
Prote AG.


♦ Ring ratchet spanner, 13 mm AF - T10384-
♦ Tool set - T10395-
satelettronica
♦ Transportation lock - T10404-
AG. Volkswagen AG d
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Removing
wit
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hole
spec
es, in part or in w

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Golf, Golf Plus, Tiguan, Touran, Eos
rrectness of i
– Disconnect connectors.
l purpos
nform
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at
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ion
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ate
do
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Cop py
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Prote AG.
Rep. gr.26 - Exhaust system

♦ -3- lambda probe - G39-
Passat, CC
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un
pt
an
d
itte
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rm
ab
– Disconnect connector -1- for exhaust gas temperature sender
pe
ility
ot
3 - G495- and connector -3- for lambda probe - G39- .
wit
, is n
h re
hole
spec
es, in part or in w
– Open heat insulation mat on cables and thread cable out of
t to the co
retainers.
– Remove lambda probe - G39- -3- and exhaust gas tempera‐
rrectness of i
ture sender 3 - G495- -1-.
satelettronica
l purpos
nform
mercia
a
com
t
– Loosen bolt -2- and remove clamp.
ion in
r
te o
– Open clip of differential pressure line on particulate filter and

thi
s
iva
pull off differential pressure line.

do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Undo and remove bolt -1- in upper bracket of particulate filter.

sulation .

AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 d b ➤ , Golf Plus 2009 ➤ , Passat 2011
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au ra
ss c
– Unscrew bolts (if any) -arrows- and remove heat shield for right
ce
le
un
pt
drive shaft.
an
d
itte
y li
Passat, CC
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Disconnect connector for exhaust gas temperature sender 4 -
nform
ercia
G648- .
m
a
com
tion in
r
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thi
s
iva
do
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rp
cum
fo
en
ng
satelettronica
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

from exhaust pipe downstream to particulate filter.
Caution

♦ Secure flexible joint.
Transportation lock - T10404- -arrow-

– Undo clamping sleeve nuts -1- and push clamping sleeve to‐
wards rear.
– Unscrew nuts -arrows- and remove front tunnel bridge.
– Unscrew nuts -1- and -2- remove rear tunnel bridge -arrows-.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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satelettronica
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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– Remove bolts -arrows- of bracket.
hole
spec
– Remove particulate filter bracket.
es, in part or in w
t to the co
Continuation for vehicles with front-wheel drive ⇒ page 351 .
Continuation for vehicles with four-wheel drive ⇒ page 352 . rrectness of i

l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Unscrew securing nuts -1- above particulate filter bracket us‐

s
iva
do
ing ratchet wrench - T10384- ; unscrew nuts -2-.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Unscrew bolts -2- and -3- for pendulum support.
– Push engine/gearbox assembly with engine support device -

3300 A- forwards by measurement -a-.
• Dimension -a- = 35 mm.
– Remove particulate filter and turn it until exhaust pipe hangs
downwards.
– Unhook rear part of exhaust system from rubber mountings.
satelettronica
– Push rear part of exhaust system as far forwards and down‐
wards as possible.
– Unscrew nuts -arrows- from underbody cover.

– Unscrew clamping washers -2- and -3-.
– Guide heat shield -1- for transmission tunnel past exhaust
wage
es n
pipes and remove. yV
olks ot g
u b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove particulate filter by turning it 180° around its own axis

through the tunnel.
nform
ercia

m
a
com
ti
– Remove subframe together with steering rack ⇒ Running

on in
gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and

r
te o
thi
installing subframe with steering rack .

s
iva
do
r
rp
– Unscrew right drive shaft from bevel box ⇒ Running gear,

um
fo
en
g
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐

n
t.
yi Co
stalling drive shaft . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew securing nuts -1- above particulate filter bracket us‐

ing ratchet wrench - T10384- ; unscrew nuts -2-.
– Take particulate filter out downwards.
Installing
• Specified torques for particulate filter ⇒ page 344 .
• Specified torque for pendulum support ⇒ page 37
• Specified torque for bolts for drive shaft heat shield ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview - drive shaft .
• Specified torque for tunnel cross-pieces: 20 Nm.
Note
♦ Renew seals, self-locking nuts and clip for particulate filter.

♦ Fit cable tie in same place when installing.
satelettronica
– Observe sequence when installing particulate filter:
olks
wage es n
ot g
V
d by ua
ran
1) Position particulate filter on turbo chargeroris and loosely at‐
e
tee
tach clip -1- auth or
ac
ss
2) Screw in bolts -2 … 5- loosely by hand
ce
e
nl
• It must still be possible to move particulate filter and
pt
du
an
bracket
itte
y li
erm
ab
ility
ot p
3) Tighten clip -1-
wit
, is n
4) Tighten bolts -2- and -5-.
h re
hole
spec
es, in part or in w
t to the co
– Installing exhaust temperature sender 4 - G648-
⇒ page 375 .
rrectness of i
l purpos
– Screw right drive shaft to bevel box ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
nform
ercia
– Install subframe together with steering rack ⇒ Running gear,

m
at
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐

om
ion
ling subframe with steering rack .

c
in t
or
his
te

a
do
priv
cum
or
– Align exhaust system free of stress ⇒ page 341 .

f
en
ng
t.
yi Co
– Install lambda probe - G39- together with lambda probe heater t. Cop py
- Z19- ⇒ page 310 .
rig
gh ht
pyri by
Vo
o
by c
– Install pressure differential sender - G505- ⇒ page 302 .
lksw
cted agen
Prote AG.
– After renewing particulate filter, carry out adaptation in “guided
functions” mode ⇒ Vehicle diagnostic tester.

gen Plus 2009 ➤ G AG. Volkswagen A
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 o➤ , aGolf
ksw , Passat
does
not 2011 ...
V l
ed bl, EA189 Gen II) - Edition 06.2019guar
y
a
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2.3 Removing and installing catalytic con‐ au ra
ss c
ce
verter
le
un
pt
an
d
itte
y li
⇒ “2.3.1 Removing and installing front exhaust pipe with catalytic
erm
ab
converter, engine codes CLCA, CLLA, CLJA”, page 354
ility
ot p
wit
2.3.1 Removing and installing front exhaust is n
h re
ole,
spec
pipe with catalytic converter, engine co‐
des CLCA, CLLA, CLJA
t to the co
rrectne
♦ Ring ratchet spanner, 13 mm AF - T10384-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
satelettronica
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ Transportation lock - T10404- Prote AG.

Removing
– Loosen bolt -2- and remove clamp.

– Unscrew securing bolt -1- from upper bracket of catalytic con‐

verter.
sulation .
– Unscrew bolts (if any) -arrows- and remove heat shield for right
drive shaft.
Caution

♦ Secure flexible joint.
satelettronica
Transportation lock - T10404- -arrow-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Undo clamping sleeve nuts -1- and push clamping sleeve to‐
t to the co
wards rear.
– Unscrew nuts -arrows- and remove front tunnel bridge.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew nuts -1- and -2- and remove rear tunnel bridge.
– Remove bolts -arrows- of bracket.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
satelettronica
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Unscrew securing nuts -1- above catalytic converter bracket
es, in part or in w
t to the co
using ratchet wrench - T10384- ; unscrew nuts -2-.
– Remove holder for catalytic converter.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew bolts -2- and -3- for pendulum support.

– Push engine/gearbox assembly with engine support device -

3300 A- forwards by measurement -a-.
• Dimension -a- = 35 mm.
agen
AG. Volkswagen AG d
o w es n
olks o
– Remove particulate
ed
by
V
filter and turn it until exhaust pipe
t gu
ara hangs
downwards.
horis nte
e t or
au a
– Unhook
ss rear part of exhaust system from rubber mountings.
c
ce
e
nl
– Push rear part of exhaust system as far forwards and down‐
pt
du
an
itte
wards as possible.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Unscrew nuts -arrows- from underbody cover.
es, in part or in w
t to the co
– Unscrew clamping washers -2- and -3-.
– Guide heat shield -1- for transmission tunnel past exhaust
rrectness of i
pipes and remove.
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove particulate filter by turning it 180° around its own axis

through the tunnel.
Installing
• Specified torques for catalytic converter ⇒ page 346 .
• Specified torque for pendulum support ⇒ page 37
• Specified torque for bolts for drive shaft heat shield ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview - drive shaft .
• Specified torque for tunnel bridges ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody panel; Removing and in‐
stalling tunnel bridge
Note
♦ Renew seals, self-locking nuts and clip for catalytic converter.


– Observe sequence when installing particulate filter:

1) Locate catalytic converter filter on turbocharger and se‐
cure clip -1- loosely
2) Screw in bolts -2 … 5- loosely by hand
• It should still be possible to move catalytic converter
and bracket.
3) Tighten clip -1-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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satelettronica
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 SCR system (selective catalytic re‐

duction)
⇒ “3.1 Assembly overview - tank for reducing agent”, page 359
⇒ “3.2 Draining reducing agent tank”, page 360
⇒ “3.3 Removing and installing reducing agent tank”, page 363
⇒ “3.4 Assembly overview - reducing agent delivery line”,
page 365
⇒ “3.5 Removing and installing reducing agent supply line”, page
366
⇒ “3.6 Removing and installing injector for reducing agent”, page
368
⇒ “3.7 Assembly overview - delivery module for reducing agent”,
page 369
⇒ “3.8 Removing and installing heater element (heater cup)”,
page 370
3.1 Assembly overview - tank for reducing agent
satelettronica
Note
swage es
♦ To keep the following
lk ot gpossible, the “NO reducing agent AUS 32” (AdBlue®) is just
description as short nas
d byV
o
ua x
called o“reducing agent”.
ran
ir se tee
th or
The au
♦ ss design and function of the SCR systems is described in ⇒ Self-study programme No. 424 ; Selective
ac
Catalytic Reduction .
ce
e
nl
pt
du
an
itte
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erm
ab
WARNING
ility
ot p
wit
, is n
h re

hole
organs.
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
3. SCR system (selective catalytic reduction) 359

1 - Upper insulation
2 - Control unit for reducing
agent heater - J891-
3 - Delivery module
❑ With pump for reducing
agent - V437- . AG. Volkswagen AG d
agen
❑ Removing and installing Volksw
oes
not
gu
⇒ page 370 ed by ara
nte
ris
o eo
4 - Reducing agent tank aut
h
ra
ss c
ce
e
nl
⇒ page 363
pt
du
an
itte
y li
5 - Evaluation unit for reducing
erm
ab
agent level - G698-
ility
ot p
wit
, is n
6 - Lower insulation
h re
hole
spec
7 - Sheet metal tray
es, in part or in w
t to the co
8 - 20 Nm
satelettronica
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3.2 Draining reducing agent tank
Note
To keep the following description as short as possible, the “NOx

reducing agent AUS 32” (AdBlue®) is just called “reducing agent”.
WARNING

organs.

♦ Vacuum box - VAS 6557-

Note
Tank for reducing agent is emptied via filler neck.
Caution
Make sure that no reducing agent gets onto the trim panels or
parts of vehicle body.
If this occurs, wash out reducing agent using clear water and
a lint-free cotton cloth.
If the reducing agent has already crystallised, use warm water
and a sponge.
Reducing agent that has not been removed will crystallise and
damage the surface after some time.
Information concerning storage and disposal ⇒ ServiceNet →
Environmental protection → Workshopn Adisposal
G. Volkswag! en
Request
country specific information from oimporter
age concerning storage
AG do
lksw es n
and disposal.
ot g
yV
satelettronica
db ua
e r an
ris tee
utho or
a ac
ss filler aperture is located under the floor
The reducing agent tank's
ce
e
covering in the luggage compartment.

nl
pt
du
an
itte
y li
– Lift floor covering -1- and push back.
erm
ab
ility
ot p
– If spare wheel -2- is present, unscrew wing nut -3- and remove
wit
, is n
wheel.
h re
hole
– Remove foam piece, if present.

spec
es, in part or in w
t to the co
WARNING rrectness of i
Protect hands when levering cap from tank filler neck.

l purpos
Risk of injury from sharp-edged body parts.

nf
ercia
orm
– Remove bung from tank filler neck -1-.

m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open tank cap -1- in luggage compartment.

Prepare vacuum box - VAS 6557- as follows:
– Close shut-off taps -A-, -B- and -C-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
– Connect coupling -D- with connection to shut-off ed tap
by V -A- and gu
ara
pressurise compressed air hose with compressed
horis air. nte
eo
aut ra
– Open cut-off tap -A-. ss c
ce
e
nl
pt
A vacuum is now created in the vacuum box - VAS 6557- .
du
an
itte
y li
– Close shut-off tap -A- as soon as pressure gauge shows a
erm
ab
ility
vacuum pressure of 0.8 bar.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect coupling -D- from connection on shut-off tap -A-

and interrupt compressed air supply at compressed air hose.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Guide end of hose -E- into filler neck to bottom of tank for re‐
ducing agent, and then open shut-off tap -B-.
Note
The reducing agent is then drawn from the tank and into the vac‐
uum box - VAS 6557- by the vacuum. The capacity of the vacuum
box - VAS 6557- is 11 litres. This extracted volume is sufficient
for removal of the reducing agent tank. If the reducing agent tank
holds a greater amount and the tank is to be emptied, then repeat
the process.
– To empty vacuum box - VAS 6557- , hold connection on shut-

off tap -C- over suitable container and open shut-off taps -A-
and -C-.
Caution
Extracted reducing agent must never be used again. Informa‐

tion concerning storage and disposal ⇒ ServiceNet → Envi‐
ronmental protection → Workshop disposal ! Request country
satelettronica
specific information from importer concerning storage and dis‐
posal.
AG. Volkswagen A
– Flush out vacuum obox agen
lksw- VAS 6557- carefully using
es n water when
G do
ot g
work sequence d bis
y complete.
V ua
r e an
ris tee
tho or
3.3 ss
au
Removing and installing reducing agent ac
ce
tank
le
un
pt
an
d
itte
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,

spec

t to the co
WARNING
rrectne

s
organs.
s o
cial p
f in

form
mer

atio
m

o
n
c
i
or
n thi
te
sd
iva
o
r
Removing
p
cum
r
fo
en
ng
t.
– Empty tank for reducing agent ⇒ page 360 . Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
n ol ot g
yV ua
db ran
– Unscrew bolts -arrows- and remove cover -A- and bracket orise
tee
-B-. au
th or
ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unclip wiring connections -A- and -B- from retainer above rear
l purpos
axle and unplug electrical connector of delivery line -B-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
satelettronica
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
– First press securing clip for line connection together in direc‐
agen
Prote AG.
tion of -arrow 1- as shown, and pull off delivery line in direction
of -arrow 2- without tools and without »jerking«.
Caution

damage to the system.
– Remove delivery module connectors -A- and -B- from their re‐
tainer above rear axle and disconnect connectors.

– Place engine and gearbox jack - V.A.G 1383 A- under reduc‐

ing agent tank.
– Unscrew bolts -arrows- and carefully lower reducing agent

tank.
Installing
Note
Ensure that all components are installed on the reducing agent
satelettronica
tank, the upper insulation is fitted properly and no lines are crush‐
ed. G. Volkswage
A n AG d
agen oes
olksw not
V
– Carefully lift reducing ed agent
by tank using engine and gearboxgu
ara
jack - V.A.G 1383horA- is until securing nuts can be fitted. nte
eo
aut ra
– Tighten securingss nuts. Specified torque ⇒ Item 8 (page 360) c
ce
le
un
pt
– Connect electric wiring and delivery line and clip into brackets.
an
d
itte
y li
rm
ab
– Fit cover -A- and bracket -B-.

pe
ility
ot
wit
, is n
– Fill reducing agent tank ⇒ Maintenance ; Booklet .

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
ti
3.4 Assembly overview - reducing agent delivery line

on in
r
te o
thi
s
iva
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r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

1 - Quick-release fastener
❑ For delivery line.
2 - Connector
❑ For heater for reducing
agent breather line -
Z104- .
3 - Reducing agent supply line
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
⇒ page 366 ed by
V gu
ara
ris nte
4 - Injector for reducing agent - aut
ho eo
ra
N474- ss c
ce
e

nl
pt
du
an
⇒ page 368
itte
y li
erm
ab
5 - Seal
ility
ot p
wit
❑ Renew
, is n
h re
hole
6 - Clip, 5 Nm
spec
es, in part or in w
❑ Renew
t to the co
satelettronica
7 - Reduction catalytic convert‐
er
rrectness of i
8 - NOx sender 2 - G687-
l purpos
❑ 50 Nm
❑ With NOx sender 2 con‐
nf
ercia
trol unit - J881- .
orm
❑ Remove right under‐
m
atio
m
body panel in order to

o
n in
c
remove and install.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3.5 Removing and installing reducing agent

supply line
Note

WARNING

organs.
– Remove left underbody cladding.

– Remove heat shield above rear axle.

– Open delivery line clips while moving upper part in

Caution

– Unclip connections from retainer above rear axle and unplug

electrical connector -B- of delivery line.
AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Caution
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Carefully expose delivery line, pull out of remaining clips and
remove.
Installing
Caution
The delivery line is pre-formed and is equipped with a heater

element over the complete length. Ensure the line is not kinked,
twisted or stretched. Otherwise, the heater element and there‐ AG. Volkswagen AG d
agen oes
ksw
by the supply line will be damaged. byV
ol not
gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Guide delivery line carefully behind brake lines and wiring har‐
wit
, is n
satelettronica
ness for electromechanical parking brake -arrows- above rear
h re
hole
axle.
spec
es, in part or in w
– Remove plug and connect delivery line to injector for reducing
t to the co
agent - N474- .
– Press delivery line into its clips from front to rear.
rrectness of i
– Close securing clips.
l purpos
– Remove plug.
nf
ercia
orm
m
atio
om
n in
c
– Connect wires -B- and supply line -A- above rear axle. Secure
or
thi
e
in retainer on body.
t
sd
iva
o
r
rp
cu
– Re-install heat shield above rear axle.
o
m
f
en
ng
t.
yi
– Re-install underbody cladding on driver side.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.6 Removing and installing injector for re‐

ducing agent
Note


WARNING

organs.
Removing
Caution

satelettronica
– Disconnect electrical connector from injector for reducing
agent - N474- .
– First press securing clip for line connection on injector for re‐
ducing agent - N474- together in direction of -arrow 1- as
shown, and pull off delivery line in direction of -arrow 2- without
tools and without »jerking«. AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
ed nte
Caution oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Open clip ⇒ Item 6 (page 366) and remove injector for reducing
spec
agent - N474- .
es, in part or in w
t to the co
Installing
– Locate injector for reducing agent - N474- with new sealing
rrectness of i
washer, taking account of lugs on reducing catalytic converter
(electrical connector faces upwards).
l purpos
– Place new securing clip over connection and push together

until it engages. This action locates the injector for reducing
nform
ercia
agent - N474- .
m
a
com
– Tighten bolt to specified torque ⇒ Item 6 (page 366) .

tion in
r
te o
– First connect electrical cable and then supply line.

thi
s
iva
do
r
rp
cum
3.7 Assembly overview - delivery module for reducing agent

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Wiring harness
2 - Delivery line
❑ for reducing agent
❑ With heater for reducing
agent line - Z104- .
❑ Assembly overview
⇒ page 365 . AG. Volkswagen AG d
agen oes
olksw not
3 - 5 Nm d by V gu
ara
rise nte
4 - Pump for reducing agent u-tho eo
ra
V437- ss a c
ce
e

nl
pt
du
an
agent pump - Z103- .
itte
y li
erm
ab
❑ With pressure sender
ility
ot p
for reducing agent me‐
wit
tering system - G686- .
, is n
h re
hole
❑ With reversal valve for
spec
reducing agent - N473- .
es, in part or in w
t to the co
5 - Seal
satelettronica
❑ Renew
rrectness of i
6 - Seal
l purpos
❑ Renew
7 - Locking ring 80 Nm
nf
ercia
o
❑ Remove and install us‐
rm
m
ing wrench - T50014- .
atio
om
n in
c
8 - Heater element (heater

or
thi
e
cup)
t
sd
iva
o
r

rp
cu
o
agent tank - Z102- .

f
en
ng
t.
yi Co
❑ With reducing agent lev‐ t. Cop py
el sender - G697-
rig
gh ht
pyri by
Vo
❑ With temperature send‐
co lksw
by
cted agen
er for reducing agent - Prote AG.
G685-
9 - Seal
10 - Filter
11 - Seal
12 - Cap
❑ For filling
❑ Accessible from luggage compartment
3.8 Removing and installing heater element

(heater cup)
Note


WARNING

organs.
♦ Seek medical attention ifagnecessary.
en AG. V
olkswagen AG
do w es n
olks ot g
byV ua
d ran
ise tee
Special tools and t or
hworkshop equipment required or
au ac
♦ Special wrench - T50014- ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove reducing agent tank ⇒ page 363 .
– Remove upper part of insulation ⇒ Item 1 (page 360) .
Caution


– Unplug connectors -arrows- at pump for reducing agent -

V437- .

Caution

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Separate connections -2- and -3-, unscrew securing
ss abolts
u ra
c
-A- and pull off pump for reducing agent - V437- upwards.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Cut cable ties -arrows- at locking ring and pull off breather line
-1- upwards.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place special wrench - T50014- onto locking ring as shown

and unscrew.
Caution
When open, only tilt cover a max. of 30° this prevents damage
to electrical cables and suction probe of delivery module.
– Open cover of delivery module, using removing wedge - 3409-

if necessary.
– Carefully reach into cup of delivery module and release it from
its locked position by turning anticlockwise.
– Remove delivery module upwards out of reducing agent tank.
Installing
– Place gasket ⇒ Item 9 (page 370) into opening in reducing
agent tank.
– Fit delivery module into reducing agententank,

AG. Vonoting
lkswagemarkings
n AG d
-A-. The marks -A- must align when
olks inserting.
wag
satelettronica
oes
not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Carefully reach into cup of delivery module and engage it by
turning clockwise. The marks -B- must align when engaged
rrectness of i
correctly.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Moisten sealing web of cover with water and carefully push
C py
ht. rig
into gasket. The marks -1- must align. rig ht
py by
co Vo
by lksw
– Put on locking ring and tighten until finger-tight.
cted agen
Prote AG.
Caution
Ensure sealing ring is not cross-threaded on threads of tank

for reducing agent. If the locking ring does not sit properly, the
consequence will be leaks and considerable corrosion dam‐
age.

– Place special wrench - T50014- onto locking ring as shown

and tighten. Specified torque ⇒ Item 7 (page 370) .
– Wash away any leaked reducing agent with water.
lkswage es n
o ot g
byV ua
– Attach cable ties -arrows- to locking ring ir seand connect breather
d ran
tee
line -1-. utho
or
a ac
ss
– Locate pump for reducing agent - V437- , attach connectors
ce
le
-2- and -3- and tighten securing bolts -A-. Specified torque
un
pt
an
d
⇒ Item 3 (page 370) .

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
– Attach connectors -arrows- to pump for reducing agent - V437-
and connect delivery line -1-.
l purpos
– Set upper part of insulation in position ⇒ Item 1 (page 360) .
nform
ercia
– Install reducing agent tank ⇒ page 363 .

m
a
com
– Check for leaks ⇒ Vehicle diagnostic tester.

tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Exhaust gas temperature regulation

⇒ “4.1 Assembly overview - exhaust gas temperature regulation”,
page 375
⇒ “4.2 Removing and installing exhaust gas temperature sender”,
page 376
4.1 Assembly overview - exhaust gas tem‐

perature regulation
Caution AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
Threads of exhaust gas temperature orise sender -G495- and - nte
G648- are coated. DO NOT also t grease with high-temperature
h eo
au ra
paste. It is imperative to tighten
ss to the torque specified below. c
Otherwise, the threaded connection can become loose and
ce
e
nl
pt
du
subsequent failures can then occur.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
1 - Turbocharger
hole
spec
2 - Control line, 45 Nm
es, in part or in w
t to the co
❑ If not fitted, seal with
dummy plugs.
rrectness of i
3 - Particulate filter
l purpos
4 - 9 Nm
5 - Bracket
nform
ercia
❑ Bolted to diesel particu‐

late filter
m
at
om
6 - Hose ion
c
in t
or
his
te
7 - Bracket
a
do
priv
❑ For pressure differential

um
for
en
g
sender - G505- .
n
t.
yi Co
op py
8 - Pressure differential sender
t. C rig
gh ht
yri
- G505- p by
co Vo
by lksw
cted
agen
Prote AG.
⇒ page 302
9 - Bracket
10 - 4.5 Nm
11 - 8 Nm
❑
sender 3 - G495- , 60 Nm
⇒ page 377
❑ Thread of sender is
coated.
grease.
13 - Lambda probe - G39- with
Lambda probe heater - Z19-
4. Exhaust gas temperature regulation 375

lkswage es n
o ot g
byV ua
d ran
ir se
CC 2010 ➤ , Eos 2006 ➤ , Golfth 2009 ➤ , Golf Plus 2009 ➤ , Passat 2011 ...
o tee
or
u
ss (2.0 l, EA189 Gen II) - Edition 06.2019
a ac
ce
e
nl
pt
du
14 - Exhaust gas temperature sender 4 - G648- , 60 Nm
an
itte
y li
erm
ab
ility
ot p
❑ Thread of sender is coated.
wit
, is n
❑ Do not additionally oil or grease.
h re
hole
spec
15 - Exhaust gas temperature sender 1 - G235- , 45 Nm
es, in part or in w
t to the co
❑ Coat with high-temperature paste; high-temperature paste ⇒ Electronic parts catalogue .
rrectness of i
l purpos
4.2 Removing and installing exhaust gas

temperature sender
nf
ercia
orm
⇒ “4.2.1 Removing and installing exhaust gas temperature sender
m
atio
m
1 G235 ”, page 376

o
n in
or c
thi
te
sd
a
3 G495 ”, page 377

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi
4 G648 ”, page 379
Co
op py
satelettronica
t. C rig
4.2.1 Removing and installing exhaust gas
gh ht
pyri by
Vo
co lksw
by
temperature sender 1 - G235- cted agen
Prote AG.

♦ Tool insert, AF 17 mm - T10395-
Removing
– Separate electrical connector -3- for exhaust temperature
sender 1 - G235- and move electrical wire aside.

Note
The threaded connection is accessible from below.
– Unscrew exhaust temperature sender 1 - G235- -item 1- from

exhaust manifold.
Installing
⇒ “4.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 375 .
Note
♦ Coat thread of exhaust gas temperature sender with high-

temperature paste; high-temperature paste ⇒ Electronic Parts
Catalogue .
satelettronica
Installation position of exhaust gas temperature sender -G235- .
• Angled shaft must have a distance -a- = 3 … 5 mm to bolting

of turbocharger support.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an

itte
y li
erm
ab
temperature sender 3 - G495-

ility
ot p
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Threads of exhaust gas temperature sender -G495- and -

G648- are coated. DO NOT also grease with high-temperature
paste. It is imperative to tighten to the torque specified
rrectness of i
⇒ page 375 . Otherwise, the threaded connection can become

loose and subsequent failures can then occur.
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
CC 2010 ➤ , Eos 2006 ➤ , Golf 2009 d by V ➤ , Golf Plus 2009 ➤ , Passat g2011
ua
ra
...
e
4-cylinder common rail engineho(2.0 l, EA189 Gen II) - Edition 06.2019 ntee
ris
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia
– Remove lambda probe - G39- with lambda probe heater - Z19-

m
at
⇒ page 310 .
om
ion
c
in t
r
– Disconnect electrical connector for exhaust gas temperature

o
his
te
sender 3 - G495- and free electrical wiring.

a
do
priv
cum
or
Golf, Golf Plus, Touran, Tiguan, connector for exhaust gas tem‐
f
en
g
satelettronica
perature sender 3 - G495- -item 1-
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Passat and CC, connector for exhaust gas temperature sender 3

- G495- - item 2-

– Unscrew exhaust temperature sender 3 - G495- -item 1-.

Installing
AG. Volkswagen AG d
agen o
• Specified torque Vol
ksw es n
ot g
⇒ “4.1 Assembly overview
d by - exhaust gas temperature regula‐
ua
ran
se
tion”, page 375tho.ri tee
o
au ra
c
Install in reverse
ss order, noting the following:
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
Fit cable tie in same place when installing.
, is n
h re
hole
spec
es, in part or in w
Installation position of exhaust temperature sender 3 - G495-
t to the co
-item 1-:
• Angled end facing left side of vehicle.
rrectness of i
• Angle -α- to mark -arrow- = approx. 17°.
l purpos
• Specified torque ⇒ page 375

– Install lambda probe - G39- together with lambda probe heater
nform
ercia
satelettronica
- Z19- ⇒ page 310 .
m
a
com
ti
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
op py
temperature sender 4 - G648-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Caution
AG.
Threads of exhaust gas temperature sender -G495- and -

G648- are coated. DO NOT also grease with high-temperature
paste. It is imperative to tighten to the torque specified
⇒ page 375 . Otherwise, the threaded connection can become
loose and subsequent failures can then occur.


Removing
– Separate electrical connector -2- for exhaust temperature
sender 4 - G648- and move electrical wire aside.
Golf, Golf Plus, Tiguan, Touran, connector for exhaust gas tem‐
perature sender 4 - G648- -item 2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
satelettronica
ce
le
Passat and CC, connector for exhaust gas temperature sender 4

un
pt
an
d
- G648-
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

nform
ercia
from exhaust pipe downstream of particulate filter.

m
a
com
Installing
ion in
r
te o
thi
s
iva
⇒ “4.1 Assembly overview - exhaust gas temperature regula‐

do
r
rp
tion”, page 375 .

um
fo
en
ng
t.
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Cop py
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5 Exhaust gas recirculation

⇒ “5.1 Assembly overview - exhaust gas recirculation”,
page 381
⇒ “5.2 Removing and installing exhaust gas recirculation cooler”,
page 382
⇒ “5.3 Checking changeover for exhaust gas recirculation cooler”,
page 384
⇒ “5.4 Checking exhaust gas recirculation cooler for leaks”, page
385
⇒ “5.5 Cleaning exhaust gas recirculation system”, page 389
5.1 Assembly overview - exhaust

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4 - Seal
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❑ Renew
5 - Vacuum line
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6 - 9 Nm
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7 - Seal
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10 - Clip, 5 Nm Prote AG.
❑ Renew
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❑ With integrated exhaust
gas recirculation valve -
N18- with exhaust gas
recirculation potentiom‐
eter - G212- .
❑ Checking changeover
⇒ page 384 .
❑ Checking exhaust gas recirculation cooler for leaks ⇒ page 385
12 - 9 Nm
13 - Seal
❑ Renew
5. Exhaust gas recirculation 381

14 - Seal
❑ Renew
15 - Exhaust gas recirculation pipe
❑ With flexible joint; do not bend flexible joint - risk of cracking
16 - 22 Nm
❑ Renew
17 - 9 Nm
18 - Seal
❑ Renew
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5.2 Removing and installing exhaust gas re‐ or eo
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Removing
– Remove catalytic converter or particulate filter ⇒ page 344 .
– Unscrew bolts for pipes -A- of exhaust gas recirculation and
remove pipes.
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
Note
satelettronica
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is
chamber bulkhead . au t or
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– Remove right drive shaft ⇒ Running gear, axles, steering;

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pe

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– Only for drive shafts bolted to gearbox: pull right flange shaft
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out of bevel box ⇒ Rep. gr. 39 ; Front final drive, Assembly

spec
overview – front final drive .

es, in part or in w
t to the co
– Unscrew bolts -1- and -3- and banjo bolt -4-.

– Open connection to oil supply line, separate support from oil
rrectness of i
supply line and remove.

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– Remove union nut -2- from turbocharger.

nform
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Note
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gr. 50 ; Plenum chamber bulkhead; Assembly overview – plenum C py
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chamber bulkhead .
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– If necessary, remove bracket between bevel box and engine
AG.
block ⇒ Rep. gr. 34 ; Bevel box; Removing and installing bevel

box


– Pinch off coolant hoses -1- and -3- with hose clamps -3094-
and remove from exhaust gas recirculation cooler; loosen
hose clamps for this.
– Remove vacuum hose -4- from vacuum unit and free.
– Unscrew bolts -arrows- and remove exhaust gas recirculation
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⇒ “5.1 Assembly overview - exhaust gas recirculation”,
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♦ Renew gaskets, seals and self-locking nuts.
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rrectness of i
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♦ Fit heat shield sleeve in the same place when installing.
nform
ercia
– Install turbocharger support with oil supply line ⇒ page 241 .

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– Check coolant level and top up as needed.

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– If exhaust gas recirculation cooler was replaced, basic setting t. Cop py
must be performed using ⇒ vehicle diagnostic tester :
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2) Drive
3) 01 - CFFA, CFFB … -engine J623
4) 01 - Engine electronics functions
5) 01 - Basic setting (Rep. Gr.23)
5.3 Checking changeover for exhaust gas

recirculation cooler

Procedure
– Remove heat shield sleeve.
– Pull vacuum hose off vacuum unit and connect hand vacuum
pump - VAS 6213- .
– Operate hand vacuum pump to create a vacuum.
• The linkage of the changeover for the exhaust gas recircula‐
satelettronica
tion cooler must move -arrows-.
If linkage does not move or only moves in jerks:
♦ Vacuum actuator is defective.
♦ Changeover flap for exhaust gas recirculation is tight.
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Fit heat shield sleeve in the same ut
places awhen installing. ra
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5.4 Checking exhaust gas recirculation
itte
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cooler for leaks ab

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Note
es, in part or in w
t to the co
A pressure of 0.8 bar is applied to the exhaust side of the exhaust

gas recirculation cooler. While so, the pressure in the cooling
system is measured.
rrectness of i
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♦ Charge air system tester - V.A.G 1687-
nform
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♦ Adapter - V.A.G 1687/11-

♦ Adapter - V.A.G 1687/15- for exhaust pipes of 60 mm and

65 mm in diameter
♦ Adapter - V.A.G 1687/16- for exhaust pipes of 55 mm in di‐
ameter
♦ Y-branch - VAS 691 005/1-
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♦ Test adapter - VAS 691 005/5-
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♦ Turbocharger tester - V.A.G 1397A-
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Test specification:
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• Coolant temperature must be at least 40 °C.

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– Screw adapter - VAS 691 005/5- onto coolant expansion tank.
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– Fit Y-branch - VAS 691 005/1- onto adapter - VAS 691 005/5- . rig ht
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– Close valve -1- for connection »C«, and open valve -2- for cted agen
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connection »A«.
– Connect hose from connection »A« of Y-branch to connection
»II« of turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
»II« (gauge pressure measurement), and switch it on. The
setting »II« must be visible.

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Connecting charge air system tester - V.A.G 1687- : s
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– If fitted, unclip wire to exhaust flap control unit -1-.
an
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– Loosen clamp -2- on exhaust pipe, and push it towards rear.
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rrectness
– On vehicles without a tunnel cross-piece, use a tensioning
o
cial p
f i
strap -2- to tie up exhaust pipe -1-.
nform
mer
atio
om
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c
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– Connect adapter - V.A.G 1687/11- with hose -A- to exhaust

pipe (engine side). Secure hose with hose clips.
Use hose -A- for exhaust pipes of 55 mm in diameter = hose
- V.A.G 1687/16- .
Use hose -A- for exhaust pipes of 60 mm and 65 mm in diam‐
eter = hose - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- to adapter -
V.A.G 1687/11- .
Prepare charge air system tester - V.A.G 1687- as follows:

– Completely unscrew pressure regulating valve -2-, close
valves -3- and -4-.
• To turn pressure regulating valve -2-, rotary knob must be
pulled upwards.
– Apply compressed air -1- to charge air system tester - V.A.G
1687- .

– Open valve -3-.

– Adjust pressure to 0.8 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.8 bar.
Note
A small amount of air escapes through the valves and enters the
engine. Therefore a holding pressure test is not possible.
Reading turbocharger tester - V.A.G 1397A- :

• Observe turbocharger tester for approx. 5 minutes.
• The pressure indicated on the turbocharger tester must not
exceed 0.025 bar. AG. Volkswagen AG d
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– If the pressure on the turbocharger tester rises above by Vol
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0.025 bar, compressed air is leaking from the exhaust side
rise into
d
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When coolant cools down, a vacuum may build up. The vacuum
wit
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is indicated by a »minus« symbol on the turbocharger tester .
h re
hole
Values preceded by a »minus« symbol do not indicate a leak! If
spec
you are uncertain, equalise the pressure in the cooling system
es, in part or in w
t to the co
and repeat the test.
rrectness of i
Cleaning Y-branch - VAS 691 005/1- :
l purpos
Note
nf
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After the leakage test has been completed, the Y-branch - VAS
m
m
atio
691 005/1- must be cleaned and any moisture which may have
om
n in
entered must be removed.
or c
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– Insert cleaning nozzle -D- into hose on connection -A- of Y

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– Open shut-off taps, and blow out hose for approx. 15 seconds. Prote AG.

5.5 Cleaning exhaust gas recirculation sys‐

tem
Note
♦ The exhaust gas recirculation module comprises the exhaust

gas recirculation cooler and the exhaust gas recirculation
valve - N18- integrated in it.
♦ It is only possible to perform the cleaning process on exhaust
gas recirculation modules as of part number - 03L 131 512
DQ/DP- .
♦ Before starting work, check the part number -1- using an en‐
doscope (e.g. VAS 6748A/1).
♦ To do this, insert endoscope between cylinder head and ex‐
haust manifold through opening in exhaust manifold -arrow-,
and guide it slightly towards right (seen in direction of travel).
♦ For reasons of clarity, the particulate filter is not shown in the
lower section of the figure.
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Explanation by Vo gu
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With some extreme modes of driving (e.g. short journeys)
uthor
there eo
is a risk of varnish and coke deposits building up onssthe
a inside of ra
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the exhaust gas recirculation cooler. In this case, the exhaust
ce
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un
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emissions warning lamp lights up in the dash panel insert, and
an
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the following codes are stored in the event memory:
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♦ P0401 “EGR system flow rate too low”
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spec
In most cases, coking or carbonisation can be eliminated by per‐
es, in part or in w
forming the flushing and cleaning procedure described as follows
t to the co
⇒ page 389 .
rrectness of i
5.5.1 Initiating cleaning of exhaust gas recir‐
culation system
l purpos
nform
ercia
♦ Cooler flushing system for exhaust gas recirculation - VAS 542

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– Open and remove clamp -1-.

– Unscrew bolts -2-, remove connecting pipe -3- to intake mani‐

fold.
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– Unscrew bolts -arrows-, pull out pipe union -1- from intake
itte
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manifold.
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– Fit adapter - VAS 542 007/7- -1- on opening of cylinder head.
wit
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rrectness of i
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nform
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– Screw in original bolts -arrows- of connecting pipe and tighten

m
by hand. Ensure that the seal on the adapter is not crimped.

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– Remove noise insulation ⇒ Rep. gr. 50 .
– Unscrew nuts -4- and bolts -5-, remove bracket.

– Open clamp -1- and remove, push particulate filter to one side.
AG. Volkswagen AG d
– Unscrew bolts -1- and nuts -2-. lksw
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– Remove connecting pipe -3- between exhaust manifold rise and
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exhaust gas recirculation cooler. utho eo
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nform
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– Release and pull off electrical connector -4- on exhaust gas
satelettronica
recirculation valve - N18- .
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Note
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For reasons of clarity, the turbocharger support is shown removed
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ng
t.
in the figure. It is not necessary to remove the support.
yi Co
Cop py
t. rig
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– Fit adapter - VAS 542 007/7- -1- on opening of exhaust gas

recirculation cooler.
– Screw in original bolts -arrows- of connecting pipe and tighten
by hand. Ensure that the seal on the adapter is not crimped.
– Join supply hose - VAS 542 007/2-2- of cleaning equipment to
adapter on exhaust gas recirculation cooler.
– Join return hose - VAS 542 007/2-3- of cleaning equipment to
adapter on cylinder head.
– Connect battery charger to vehicle battery.
– Connect terminal clamps of valve positioner - VAS 542 007/6-
to vehicle battery.
– Connect terminal clamps of pump - VAS 542 007/3- to vehicle
battery.
Prepare cooler flushing system for exhaust gas recirculation -
VAS 542 007-
– Fill canister - VAS 542 007/1- with 9 litres of warm (approx.
40°C - 50°C) tap water.
– Pour 1 litre of cleaning solution - D 600 200 A2- into the can‐
ister.
– Join suction hose - VAS 542 007/2-1- of pump to connection
-1- on canister lid.

AG . Volkswage
– Insert open end of return hose - VAS ksw
542
agen 007/2-3- into opening
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-arrow- of canister lid up to approx.
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– Fit connector of valve adjuster
ut
ho
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- VAS 542 007/6- on exhaust tee
or
gas recirculation valve
ss a - N18- . ac
ce
– Switch on valve adjuster - VAS 542 007/6- to open exhaust e
nl
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gas recirculation valve.
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♦ Ensure that the tap of the relief valve on the supply hose is
es, in part or in w
closed.
t to the co
♦ If activation of the exhaust gas recirculation valve via the valve
adjuster - VAS 542 007/6- including approx. 1.6 bar pressure
rrectness of i
from the pump - VAS 542 007/3- is not sufficient to open the
exhaust gas recirculation valve, the pump switches off after a
l purpos
brief period. In this case, the exhaust gas recirculation valve

has a mechanical defect and the exhaust gas recirculation
valve must be renewed. Before disconnecting the supply
nf
ercia
o
hose, carefully open the relief valve tap to release the pressure
rm
m
and collect the escaping cleaning solution.
atio
m
satelettronica
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– While the cleaning process is running, clean the connecting
te
sd
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pipes ⇒ page 394 .

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– Actuate pump - VAS 542 007/3- as follows:
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Switch on 25 min. Clean
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Switch off 10 min. Period for cleaning

solution to take ef‐
fect
Switch on 25 min. Clean
Switch off --- End of cleaning
process
– Disconnect intake hose from canister, switch on pump until no
more cleaning solution is delivered (system is emptied in doing
so).
– Pull out return hose from canister, pay attention to escaping
cleaning solution.
– Empty canister, observe country-specific disposal regulations.
– Fill canister with 10 litres of warm (approx. 40°C - 50°C) tap
water.
– Join suction hose - VAS 542 007/2-1- of pump to connection
on canister lid.
– Feed return hose - VAS 542 007/2-3- into a suitable container
(with a capacity of at least 12 litres) and secure in place.
– Switch on pump - VAS 542 007/3- until entire contents of can‐
ister have flown through exhaust gas recirculation system.
– Release and pull off supply hose - VAS 542 007/2-2- from
adapter on exhaust gas recirculation cooler.
– Connect compressed air adapter - VAS 542 007/5- to adapter
on exhaust gas recirculation cooler.
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- of canister lid up to approx. half canister height.

– Suction hose - VAS 542 007/2-1- of pump must be joined to

connection -1- on canister lid.
– Fit compressed air line to compressed air adapter - VAS 542
007/5- , and completely blow out remaining water from ex‐
haust gas recirculation system.
Caution
The water must be removed from the exhaust gas recirculation

system without trace. Otherwise there may be problems with
starting the engine.
– Release and pull off compressed air adapter - VAS 542

007/5- .
– Detach adapter from exhaust gas recirculation cooler.
– Pull off connector of valve adjuster - VAS 542 007/6- from ex‐
haust gas recirculation valve - N18- , fit original connector.
– Check effectiveness of cleaning with ⇒ Vehicle diagnostic
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EDC 17
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♦ 01 - Engine electronics functions
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♦ 01 - Checking exhaust gas recirculation valve 1 -
h re
hole
GX5- after cleaning in accordance with workshop
spec
es, in part or in w
manual
t to the co
If the result of the test is »Not OK«, the exhaust gas recirculation
cooler with integrated exhaust gas recirculation valve - N18- must
be renewed ⇒ page 382 .
rrectness of i
After cleaning has been successfully conducted:
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– Install connecting pipe with new seals and new nuts

⇒ page 381 .
nf
ercia
orm
– Bring particulate filter to installation position with new gasket
m
atio
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and new clamp, and secure it ⇒ page 353 .

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– Fit noise insulation ⇒ Rep. gr. 50 .

thi
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– Release and pull off return hose on cylinder head adapter.

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– Insert pipe union -1- in intake manifold. Note: opening of union

t.
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points towards throttle valve module. C py
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– Screw in bolts -arrows- and tighten to 9 Nm.
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4-cylinder common railedengine
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– Remove adapter on cylinder
ss
au
head, install connecting pipe with ra
c
new seal ⇒ page 381 .
ce
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nl
pt
du
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itte
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erm
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– Carry out road test.
ility
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– Therefore, read event memory and erase entries if necessary.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
5.5.2 Cleaning connecting pipes and pipe un‐

ion
nform
ercia

m
at
om
ion
c
♦ Ultrasonic cleaning device - VAS 6418-
in t
or
his
ate
– Close drain tap -arrow- of ultrasonic cleaning unit - VAS 6418-
do
riv
at right-hand side of housing.

p
cum
satelettronica
for
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ng
t.
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The ultrasonic bath can be heated up faster by using warm tap
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water.
– Fill ultrasonic cleaning device - VAS 6418- with 1800 ml of tap

water and 200 ml of cleaner - D 600 200 A2- .
– Insert connecting pipes and pipe union. Adjust position of con‐
necting pipes in bath where necessary.
– Switch on cleaning unit by pressing on/off button -C-.
– Turn rotary temperature switch -B- until lamp indicator is at 40°

C warm-up temperature
– Set rotary switch for operating period -A- to “10” -arrow-.
– Press and hold ► -D- for longer than 2 seconds and, in doing
so, bring equipment into operation.
Note
Temperature-controlled cleaning is now activated. During the

warm-up period, ultrasonic waves are activated to mix the clean‐
ing fluid. Once the preselected temperature is reached, the ultra‐
sonic waves are switched to continuous operation. Cleaning time
must be at least 10 minutes, and cleaning only starts at a tem‐
perature of at least 40°C.
– Once cleaning is complete, flush connecting pipes and pipe

union with clean water and blow out with compressed air.

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Removing and installing glow plug”, page 395
⇒ “1.2 Removing and installing automatic glow period control
unit”, page 397
⇒ “1.3 Removing and installing Hall sender”, page 398
⇒ “1.4 Removing and installing engine speed sender”,
page 398
1.1 Removing and installing glow plug

♦ T-bar and socket, 10 mm - 3220-
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♦ Pliers - 3314-
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♦ Ensure that no cable connection is damaged when dis‐

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♦ Do not compress the pliers - 3314- too firmly to separate

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1. Glow plug system 395

– Open retaining clips -arrows- of wiring harness and pull elec‐

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– Position pliers - 3314- with groove -arrow A- on support sleeve
shoulder -arrow B- and pull connectors off glow plugs.
– Clean glow plug port in cylinder head; make sure no dirt gets
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♦ Use a vacuum cleaner to remove coarse dirt.
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– Loosen glow plugs using U/J extension and socket, 10 mm -
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3220- .
Installing
• Specified torque: 18 Nm
– Reattach glow plug connectors -1- to glow plugs -arrow-.
Note
Make sure that glow plug connectors are firmly seated.
396 Rep. gr.28 - Glow plug system

1.2 Removing and installing automatic glow

period control unit
The automatic glow period control unit - J179- is located in the
relay and fuse holder in the electronics box in the plenum cham‐
ber.
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– Pull out relay holder under electronics box in engine compart‐

ment -arrow-.
– Pull automatic glow period control unit - J179- -item 1- out of
its slot in relay holder under electronics box in engine com‐
partment.
Installing
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .

1.3 Removing and installing Hall sender

Fitting location ⇒ Item 3 (page 113)
sulation .
– Release and disconnect connector -1- from Hall sender -
G40- .
– Unclip connector on water pipe.
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– Remove webs with a screwdriver and take out repair aperture

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– Remove Hall sender - G40- from cylinder head and insert its
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♦ Seal repair aperture in toothed belt guard with rubber plugs as
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specified in ⇒ Electronic Parts Catalogue (ETKA) .
Specified torque
Component Specified torque
Hall sender - G40- on the cylinder head 10 Nm
1.4 Removing and installing engine speed

sender

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Fitting location ⇒ Item 5 (page 91)
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– Clamp off coolant hoses from the engine oil cooler using hose
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Collect escaping coolant with drip tray - VAS 6208- .
– Pull coolant hoses off engine oil cooler.

– Remove oil filter bracket with engine oil cooler ⇒ page 188
– Release and pull off connector on engine with assembly tool

- T10118- .

– Loosen securing bolt -arrow- with socket AF 4 mm - T10370-

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Specified torques
Component Specified torque
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Engine speed sender - G28- 5 Nm
Oil filter bracket ⇒ “2.2 Removing and installing engine oil cooler”, page 188
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Service

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Service

Scirocco h2009 ➤ , Tiguan 2008 tee ➤ ,

4-cylinder common rail engine (2.0 l, EA189 Gen II)

CLJA CFG CFH

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D3E80251958

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.5 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 spec

2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

2.4 Removing and installing coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

1.2 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

1.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

2.1 Assembly overview - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

3.7 Assembly overview - delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 369

4 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 382

1.1 Engine number/engine data

1.1.1 Engine number

1.1.2 Engine data

Codes CFFA CFFB CFFD CFHB CFHC CFH CFGB CFG

Golf --- --- --- 11.09 ► 11.09 ► --- --- ---

Ti‐ 05.10 ► 11.09 ► 05.10 ► --- --- --- 05.10 ► 11.1

Tour‐ --- --- --- --- 08.10 ► 05.1 --- 0

Eos 11.10 ► 11.10 ► --- --- --- --- --- ---

CC 10.10 ► 10.10 ► --- --- --- 12.1 --- 10.10 ►

Pas‐ 10.10 ► 10.10 ► --- --- --- --- 10.10 ► 12.1

1) only for India, South America and Russia

2) Particulate reduction system instead of particulate filter

2 Rep. gr.00 - Technical data

Fuel poses danger of injury to eyes and skin.

Wear protective goggles and protective clothing to avoid injury

To prevent injuries to persons and destruction of the injection and

♦ Wash the engine only with the ignition switched off.

♦ Observe measures for disconnecting battery ⇒ Electrical

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

2.2 Safety precautions when using testers

2.3 Safety measures when working on ve‐

♦ You must therefore ensure that the Start/Stop system is

switch ignition on again as required).

The cooling system is under pressure when the engine is hot!

Danger of overheating due to incorrectly fitted cap.