Engine Czca Czda CZDB Djka CZDC Repair Manual Eng

Service
Workshop Manual
CC 2012 ➤, Golf 2020 ➤,
Golf Cabriolet 2012 ➤,
Golf Variant 2021 ➤, Scirocco 2015 ➤,
Sharan 2016 ➤, T-Roc 2018 ➤,
Tiguan 2008 ➤
4-cylinder direct injection engine (1.4 l engine, 4V,
EA 211, turbocharger)
Engine ID
CZC CZD CZD DJKA CZD
A A B C
Edition 08.2020
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
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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.
CC 2012 ➤, Golf 2020 ➤, Golf Cabriolet 2012 ➤, Golf Variant 2021 ➤, Scirocco 20 ...
4-cylinder direct injection engine (1.4 l engine, 4V, EA 211, turbocharger) - Edition 08.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Removing and installing gearbox mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 117
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.1 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Contents i
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.6 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.7 Setting piston to TDC position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.4 Preassembling and installing valve timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.6 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.7 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2.8 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.3 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3.4 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3.6 Removing and installing exhaust camshaft control valve 1 N318 . . . . . . . . . . . . . . . . . . . . 283
3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 314
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
ii Contents
4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 325
4.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.5 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 328
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
2.7 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 366
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 367
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . . . 370
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 399
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 426
1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 438
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
2.5 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
2.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
3.3 Removing and installing air guide on lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Contents iii
3.4 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476

4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
5.1 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
5.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
5.4 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . 493
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
6.1 Assembly overview - engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
6.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
6.3 Removing and installing engine (motor) control unit J623 with protective housing . . . . . . 502
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
8.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
1.4 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 580
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
iv Contents
00 – Technical data
1 Safety information
(VRL014321; Edition 08.2020)
⇒ r1.1 egulations for working on fuel supply”, page 1
⇒ m1.2 easures when working on vehicles with start/stop sys‐
tem”, page 1
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on the cooling system”, page
2
⇒ p1.5 recautions when working on ignition system”, page 2
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the
door contact switch activates the fuel pump. Escaping fuel can
ignite and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety measures when working on vehicles with start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle’s start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring
equipment on the rear seat.
1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
When the motor is hot, the cooling system is under high pres‐
sure. Danger of scalding by steam and hot coolant.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
1.5 Safety precautions when working on ignition system

Risk of injury due to electric shock
The ignition system is under high voltage when the engine is
running. Touching the ignition system may result in an electric
shock.
– Do not touch or disconnect ignition cables when the engine
is running or being turned at starter speed.
Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting
electric cables.
– Switch off the ignition before washing the engine.
2 Rep. gr.00 - Technical data

2 Identification
⇒ n2.1 umber/engine data”, page 3
2.1 Engine number/engine data

The engine code and the engine number are located on the
sticker -arrow- on the upper toothed belt guard.
The engine code is also on the vehicle data sticker and on the
crankcase above the gearbox.
The engine number consists of up to 9 characters (alphanumer‐
ic). The first part (max. 3 letters) represents the “engine code”.
The second part (six characters) represents the “serial number”.
After 999,999 engines with the same code letters have been
produced, the first of the six digits is replaced by a letter.
Vehicles with four digit engine codes
Four-place engine codes are being introduced, starting with let‐
ter “C”. The first 3 places show the mechanical design of engine
and are stamped on the engine as previously. The fourth digit
denotes the performance and torque rating of the engine and
depends on the engine control unit -J623-. The four-digit engine
code can be found on the identification plate, the vehicle data
sticker and on the engine control unit.
Note
Fitting locations of vehicle data sticker ⇒ Maintenance; Booklet ;

Vehicle data sticker.
Engine code CZDA CZDB CZDC CZCA DJKA

Manufactured 05.14 ► 05.14 ► 05.15 ► 04.15 ► 08.18 ►
Exhaust emission EU 6 EU 6 EU 6 EU6AG
standard
Displace‐ cm3 1395 1395 1395 1395 1395
ment
Power kW 110/5000-6000 92/5000-6000 96/5000-6000 92/5000-6000 110/5000
at
rpm
Torque Nm 250/1500-3500 200/1400-4000 200/1400-4000 200/1400-4000 250/1500-4000
at
rpm
Bore Di‐ 74.5 74.5 74.5 74.5 74.5
ame
ter,
mm
Stroke mm 80.0 80.0 80.0 80.0 80.0
2. Identification 3
Engine code CZDA CZDB CZDC CZCA DJKA

Compression ratio 10.0 10.0 10.0 10.0 10.5
Valves per cylin‐ 4 4 4 4 4
der
RON min. 95 unleaded (in 95 unleaded (in 95 unleaded (in 95 unleaded (in 95 unleaded (in
exceptional cir‐ exceptional cir‐ exceptional cir‐ exceptional cir‐ exceptional cir‐
cumstances cumstances cumstances cumstances cumstances
min. 91 RON, min. 91 RON, min. 91 RON, min. 91 RON, min. 91 RON,
however with however with however with however with however with
reduced per‐ reduced per‐ reduced per‐ reduced per‐ reduced per‐
formance) formance) formance) formance) formance)
Injection, ignition Motronic ME 17 Motronic ME 17 Motronic ME 17 Motronic ME 17 Motronic
system MED 17/01/202
7
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Volkswagen Technical Site: https://vwts.ru

3 Repair notes
⇒ f3.1 or cleanliness”, page 5
⇒ i3.2 nformation”, page 5
⇒ r3.3 epair instructions”, page 5
⇒ o3.4 bjects in engine”, page 7
⇒ c3.5 orrosion”, page 7
⇒ a3.6 nd attachment of lines”, page 7
⇒ r3.7 adiator and condensers”, page 7
⇒ v3.8 acuum system”, page 7
3.1 Rules for cleanliness

When working on the fuel supply and injection system, pay
particular attention to the following rules for cleanliness:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ 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.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Make sure that no fuel gets onto the coolant hoses. Should
this occur, the coolant hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and wa‐
ter, and reconnect them only when dry.
3.2 General information

♦ For the applicable current flow diagrams, refer to ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
3.3 General repair instructions

⇒ n3.3.1 otes on injection”, page 5
⇒ n3.3.2 otes on ignition system”, page 6
⇒ n3.3.3 otes on charge air system”, page 6
3.3.1 General notes on injection

♦ The engine control unit has a self-diagnosis capability.
Before carrying out repairs and fault finding, read event
memory. Also the vacuum hoses and connections must be
checked (unmetered air).
♦ Fuel hoses in engine compartment may only be secured with
spring-type clips ⇒ Electronic parts catalogue (ETKA). The
use of crimp-type or screw-type clips is not permissible.
♦ For trouble-free operation of electrical components, a volt‐
age of at least 11.5 V is necessary.
3. Repair notes 5
♦ Do not use sealants containing silicone. Particles of silicone

drawn into the engine will not be burnt in the engine and
damage the Lambda probe.
♦ Certain tests may lead to a fault being detected by the
control unit and stored. Therefore, after completing all the
checks and repairs, read the event memory and clear it if
necessary ⇒ Vehicle diagnostic tester.
3.3.2 General notes on ignition system

♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control
unit could be damaged.
♦ The engine control unit and other components feature self-
diagnosis; checking ⇒ Vehicle diagnostic tester.
♦ For trouble-free operation of electrical components, a volt‐
age of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected by the
control unit and stored. Therefore, after completing all the
checks and repairs, read the event memory and clear it if
necessary ⇒ Vehicle diagnostic tester.
Safety precautions ⇒ p1.5 recautions when working on ignition
system”, page 2 .
Setting data, spark plugs:⇒ Maintenance; Booklet ; Service ta‐
bles
3.3.3 General notes on charge air system

When performing any repair work, especially in the engine com‐
partment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines (e.g. for fuel, hydraulics, coolant
and refrigerant, brake fluid and vacuum) and electrical ca‐
bles in their original positions.
♦ Ensure that there is sufficient clearance to all moving or hot
components.
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
must be carried out:
♦ Clean any oil lines.
♦ Change engine oil and renew oil filter.
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ The charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ To secure hose connections, use only approved clamps
⇒ Electronic parts catalogue (ETKA).
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Before connecting oil supply line, fill turbocharger at union
with engine oil.

♦ After installing turbocharger, run engine for about 1 minute

at idling speed to ensure that oil is supplied to the turbo‐
charger.
3.4 Foreign objects in engine

Prevent the ingress of foreign bodies during work on the en‐
gine.
Seal open channels and connections using suitable plugs from
the engine bung set -VAS 6122-.
3.5 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue (ETKA).
3.6 Routing and attachment of lines

♦ Mark the lines for the fuel, hydraulic and vacuum systems
and for the activated charcoal filter system as well as electri‐
cal lines before they are removed.
♦ Where necessary, make sketches or take photographs.
♦ To avoid damaging pipes and wires, ensure adequate clear‐
ance from all moving or hot components in the engine com‐
partment on account of the confined space.
3.7 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does
not mean that these components have been damaged. It is
not permissible to renew radiators, condensers or charge air
coolers only because of such minor dents.
3.8 Checking vacuum system

Special tools and workshop equipment required
♦ Hand operated vacuum pump -VAS 6213-
Sequence of operations
– Check all vacuum lines throughout entire vacuum system
for:
♦ Cracks
3. Repair notes 7
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid
valve to relevant component.
– If a fault has been entered in the event memory, make sure
to check not only all vacuum lines leading to the specified
component, but also those leading to other components.
– If pressure cannot be built-up using hand vacuum pump
-VAS 6213- or pressure immediately drops again, check
hand vacuum pump and connecting hoses for leaks.

10 – Removing and installing engine

1 Removing and installing motor
⇒ m1.1 otor”, page 9
⇒ e1.2 ngine and gearbox”, page 60
⇒ e1.3 ngine on engine and gearbox support”, page 61
⇒ e1.4 ngine”, page 63
1.1 Removing motor

⇒ e1.1.1 ngine, Golf Cabriolet and Scirocco”, page 9
⇒ e1.1.2 ngine, Sharan, CC and Tiguan”, page 22
⇒ e1.1.3 ngine, T-Roc”, page 36
⇒ e1.1.4 ngine, Golf 2020, Golf Estate 2021”, page 45
1.1.1 Removing engine, Golf Cabriolet and

Scirocco
♦ Release lever -80 - 200-
♦ Extension -2024 A /1- of lifting tackle -2024 A-
1. Removing and installing motor 9

♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Engine support -T10497-
♦ Drip tray for workshop hoist -VAS 6208-
♦ Spring-type clip pliers -VAS 6362-
10 Rep. gr.10 - Removing and installing engine

♦ Engine and gearbox jack -VAS 6931-
♦ Locking pin -T10060 A-
♦ Engine bung set -VAS 6122-
♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
Note
♦ The engine is removed downwards together with the gear‐

box.
♦ Reinstall all cable ties in the same locations when installing.
– Open filler cap -1- on coolant expansion tank.

CAUTION
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.
– Remove air filter housing ⇒ a3.2 nd installing air filter hous‐

ing”, page 472 .
– Release hose clip -1- and detach air intake hose.
– Unclip upper part -2- of air duct, and remove it.

– Unclip lower part of air duct, and remove it.
– Remove air pipe ⇒ a2.5 nd installing air pipe”, page 441 .
– Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27;
Battery; Removing and installing battery tray.
– Open plug-in connectors -1- and -2- of fuel lines, and pull
off fuel lines. Disconnect plug-in connectors ⇒ Rep. gr. 20;
Plug-in connectors; Disconnecting plug-in connectors.

– Move lines to one side.

– Remove activated charcoal filter ⇒ Rep. gr. 20; Activated
charcoal filter system; Removing and installing activated
charcoal filter.
– Unscrew bolt -4- and turn filler neck for washer fluid reser‐
voir -2- towards front.
– Open clip -3- and pull connector -5- off coolant expansion
tank -1-.
– Unscrew bolts -arrows-, and place coolant expansion tank
-1- on engine with coolant hoses connected.
– For the work steps below use removal lever -80 - 200- to
unclip the binding clips.
– Release and pull off connector on engine control unit -J623-

⇒ c6 ontrol unit”, page 495 .
– Open cable duct latches on longitudinal member -arrows-.

– Release feed-through for engine wiring harness -arrow-, and

pull it off upwards.
– Release and disconnect connectors -1- and -2-.
– Open locking elements -arrows- of cable guide, and place

engine wiring harness -3- on engine.
– Move electrical lines free.
– Secure cables to engine using a cable tie.
– Disconnect electrical connector -2-.

– Push back cover for battery positive terminal -1-, and unbolt
battery positive cable from starter solenoid switch.
– Unbolt earth wire from body.
– Release fasteners -1- in -direction of arrow-, and remove
cover -2- for electronics box in engine compartment.
– Remove nut -arrow-, detach electrical wiring and move clear.

Manual gearbox
– Separate electrical connectors -1- and -2-.

– Remove selector mechanism from gearbox ⇒ Rep. gr. 34;
Selector mechanism; Removing and installing selector
mechanism.
– Remove clutch slave cylinder ⇒ Rep. gr. 30; Clutch mecha‐
nism; Removing and installing clutch slave cylinder.
– Do not remove line from clutch slave cylinder while doing so.
– Lay clutch slave cylinder with clutch line connected to one
side.
Dual clutch gearbox
– Remove selector lever cable, pull connector of mechatronic
off and remove all retainers from gearbox:⇒ Rep. gr. 34;
Removing and installing gearbox
Continued for all vehicles
– Unscrew bolts -arrows- on engine mounting approx. 2 turns.

– Unscrew bolts -arrows- on gearbox mounting approx. 2
turns.

– Remove left and right front wheel ⇒ Running gear, axles,

steering; Rep. gr. 44; Wheels, tyres and alignment.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove left and right front wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66; Wheel housing liners;
Assembly overview - front wheel housing liner.
Vehicles with air conditioning system
– Remove poly V-belt ⇒ a1.3 nd installing poly-V belt”, page
129 .
– Remove air conditioner compressor with refrigerant lines
connected from engine ⇒ Heating, air conditioning; Rep.
gr. 87; Air conditioner compressor; Removing air conditioner
compressor from and installing to bracket.
– Remove air conditioner compressor (with refrigerant lines
connected) from bracket, and secure it to vehicle.
– Unscrew bolt -2- and remove screw-type clip.

– Unscrew bolt -1- and nuts -arrows-, and secure catalytic
converter to vehicle.

– Undo bolts -arrow- and remove bracket.

– Disconnect electrical connector -1- on oil level and oil tem‐
perature sender -G266-.
– Detach wire from retainer -2-.

– Remove coupling rod on anti-roll bar ⇒ Running gear, axles,
steering; Rep. gr. 40; Subframe; Removing and installing
coupling rod.
– Remove pendulum support ⇒ a2.4 nd installing pendulum
support”, page 87 .
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40; Drive shaft; Removing and in‐
stalling drive shaft heat shield.
– If fitted, unbolt front left vehicle level sender -G78- on trans‐
verse link ⇒ Running gear, axles, steering; Rep. gr. 43; Ve‐
hicle level sender; Assembly overview - front vehicle level
sender.
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40; Drive shaft; Removing and installing drive shaft, raise
and tie.
– Swivel front left suspension strut outwards and support with
extension -2024 A /1-, as shown in illustration.

– Secure locking pin and swivel joint with locating pin -arrow-
and nut -1-.
– Secure swivel joint -2- (right-side) to transverse link -1- with
nut -arrow-, as shown in illustration.
– Remove radiator cowl ⇒ a4.5 nd installing radiator cowl”,

page 407 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.
– Place drip tray for workshop hoist -VAS 6208- underneath.

– Drain coolant ⇒ a1.3 nd adding coolant”, page 340 .
– Lift retaining clip -arrow- and disconnect coolant hose (top
left) from radiator.


right) from water radiator for charge air cooling circuit.
Vehicles with no auxiliary heater
– Lift retaining clips -arrows- and disconnect coolant hoses

from heat exchanger for heater.
Vehicles with auxiliary heater

– Release retaining clip and hose clip and pull off both coolant
hoses -arrows-.
– Release hose clip -1- and pull off coolant hose.

– Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration.
– Position engine support T10497 with pin T10497/1 on cylin‐

der block.
– Screw in bolt -1- through hole “B” in engine support T10497
and tighten it to 20 Nm.
– Fit adapter -T10497/3- to engine support -T10497- and tight‐
en bolt -1- to 20 Nm.

– Insert engine and gearbox jack in engine support T10497

and raise engine/gearbox assembly slightly.
Note
To unscrew bolts for assembly mounting use commercially

available stepladder.
– Remove bolts -arrows- for engine mounting.
– Remove bolts -arrows- securing gearbox mounting.
– Check that all vacuum lines and electrical wiring between

engine, gearbox, subframe and body have been detached.
– When lowering, carefully guide engine/gearbox assembly
with assembly carrier out of engine compartment.
– First lower engine/gearbox assembly slightly.
– Then push gearbox end of engine/gearbox assembly for‐
wards and only then lower further.
1.1.2 Removing engine, Sharan, CC and Ti‐

guan

♦ Release lever -80 - 200-
♦ Engine and gearbox jack -V.A.G 1383 A-


♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
Note

box.
– Open filler cap -1- on coolant expansion tank.
CAUTION

ing”, page 472 .


CC:
Sharan with petrol particulate filter
– Pull off connector -a- from activated charcoal filter line -b-.
– Unclip activated charcoal filter line -b- and fuel line -c- from
bracket -d-.
– Place activated charcoal filter lines -b- and fuel line -c- aside.
Continued for all vehicles:
tank -1-.

Note
For the work steps below use removal lever -80 - 200- to unclip
the binding clips.
– Release and pull off connector on engine control unit -J623-

⇒ c6 ontrol unit”, page 495 .
– Open cable duct latches on longitudinal member -arrows-.
– Release and disconnect connectors -1- and -2-.
– Open locking elements -arrows- of cable guide, and place

engine wiring harness -3- on engine.

– Secure cables to engine using a cable tie.

– Push back cover for battery positive terminal -1-, and unbolt
battery positive cable from starter solenoid switch.
– Release fasteners -1- in -direction of arrow-, and remove
cover -2- for electronics box in engine compartment.

Manual gearbox
– Separate electrical connectors -1- and -2-.

mechanism.
– Do not remove line from clutch slave cylinder while doing so.
– Lay clutch slave cylinder with clutch line connected to one
side.
Dual clutch gearbox
– Remove brake servo vacuum pump ⇒ Rep. gr. 47; Vacuum
system; Assembly overview – electric vacuum pump.

turns.


insulation.
Tiguan:
– If fitted, remove cross piece -1-. To do this, unscrew bolts

-arrows-.
page 407 .
illustration.






hoses -arrows-.
– Release hose clip -1- and pull off coolant hose.

129 .
– Remove connectors -1- and -2- from retainer, release them,
and pull them off.



– Detach wire from retainer -2-.

– Remove coupling rod on anti-roll bar ⇒ Running gear, axles,
steering; Rep. gr. 40; Subframe; Removing and installing
coupling rod.
– If fitted, unbolt front left vehicle level sender -G78- on trans‐
verse link ⇒ Running gear, axles, steering; Rep. gr. 43; Ve‐

hicle level sender; Assembly overview - front vehicle level

sender.
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40; Drive shaft; Removing and installing drive shaft, raise
and tie.
and nut -1-.
– Apply clamping piece T10497/2 at housing rib on cylinder

block, as shown in illustration.

– Position engine support T10497 with pin T10497/1 on cylin‐

der block.
– Screw in bolt -1- through hole “B” in engine support T10497
and tighten it to 20 Nm.
– Insert engine and gearbox jack in engine support T10497

and raise engine/gearbox assembly slightly.
Note

– Check that all vacuum lines and electrical wiring between



1.1.3 Removing engine, T-Roc

♦ Removal lever -80 - 200-
♦ Engine and gearbox jack -V.A.G 1383 A- or -VAS 6931-


♦ Protective mat -VAS 531003- (not shown)

♦ Commercially available stepladder (not shown)
♦ Safety glasses
♦ Safety gloves
Note

box.
CAUTION
– Open filler cap -arrow- for coolant expansion tank.

ing”, page 472 .
– Unclip gearbox breather from battery tray.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27; Bat‐
tery; Removing and installing battery tray.

– If fitted, remove vacuum pump for brakes -V192- ⇒ Brake

system; Rep. gr. 47; Vacuum system; Removing and instal‐
ling electric vacuum pump (for brakes).
– Release vacuum hose -1- -arrow-, and pull it off.
– Move clear vacuum hose at air pipe -2-.
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
– Release and pull off electrical connector -1-.

– Disconnect bracket -2- with fuel hoses.

– Use a screwdriver to release catch -arrow-, and place cool‐
ant expansion tank on engine.
– Release and pull off electrical connector -1- on engine con‐

trol unit -J623- ⇒ c6 ontrol unit”, page 495 .

and pull them off.
– Release catch -arrows-, and remove cover -1- for electronics
box in engine compartment.
– Use a screwdriver to release catch -arrow-, and pull off cov‐

er -1- for electronics box in engine compartment upwards.


insulation.
– Release and pull off electrical connector on starter ⇒ Elec‐
trical system; Rep. gr. 27; Starter; Removing and installing
starter.
– Unscrew B+ wire from starter solenoid switch ⇒ Electrical
system; Rep. gr. 27; Starter; Removing and installing starter.
– Release and pull off electrical connector from gearbox
⇒ Rep. gr. 34; Removing and installing gearbox.
mechanism.
– Unbolt earth cable on gearbox.
– Remove lower front wheel housing liner on left and right
⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview - front wheel housing liner.
page 407 .
illustration.

Vehicles with air conditioner:

129 .
– Release and pull off connector on oil level and oil temper‐
ature sender -G266- ⇒ a1.6 nd installing oil level and oil
temperature senderG266”, page 314 .
– Remove heat shield from turbocharger ⇒ page 191 .
– Remove catalytic converter from engine, put it aside, and
secure it to vehicle ⇒ a2.2 nd installing catalytic converter”,
page 570 .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
– Remove left drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.


– Place a cloth underneath heat exchanger for heater to catch

escaping coolant.


turns.
– Position clamping piece -T10497/2- on housing rib of cylin‐

der block as shown in illustration.
– Position engine bracket -T10497- with pin -T10497/1- on

cylinder block.
– Screw in bolt -1- through hole “B” in engine support -
T10497- and tighten to 20 Nm.
– Insert engine and gearbox jack -V.A.G 1383 A- in engine

support -T10497- and raise engine/gearbox assembly slight‐
ly.

– To unscrew bolts for assembly mounting use commercially

– Completely unscrew bolts for engine mounting.
– Completely unscrew bolts for gearbox mounting.
NOTICE
Danger of damage to lines and hoses as well as engine com‐
partment as engine/gearbox assembly is lowered.
– Check that all connections between engine, gearbox, sub‐
frame and body have been disconnected.

– Push gearbox end of engine/gearbox assembly forwards,
and only then lower further.
1.1.4 Removing engine, Golf 2020, Golf Es‐

tate 2021
♦ Removal lever -80-200-

♦ Engine support -T10497B-

♦ Protective mat -VAS 531003- (not shown)

♦ Commercially available stepladder (not shown)
♦ Commercially available drip tray (not shown)
♦ Safety glasses
♦ Safety gloves
Note

box.
– Open filler cap -arrow- of coolant expansion tank.
CAUTION

ing”, page 472 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and reconnecting battery.

– Remove battery and battery tray ⇒ Electrical system; Rep.

gr. 27; Battery; Removing and installing battery tray.
– Release catch -arrow- and disconnect vacuum hose -1-.

CAUTION

– Remove coolant hoses from engine. To do this, open retain‐

ers.
– Using a screwdriver, release fasteners -arrow- and move
coolant expansion tank to one side.
Vehicles with fuel quality sender -G446-:
– Remove fuel quality sender -G446- from engine mounting
⇒ Rep. gr. 20; Senders and sensors; Overview of fitting
locations - senders and sensors.
– Unplug upper electrical connector -1- at engine control unit
-J623- ⇒ c6 ontrol unit”, page 495 .
– Remove electrical connectors -2- and -3- from retainer and

disconnect.
– Release catches -arrows- and detach cover -1- for electron‐
ics box in engine compartment.

– Release catch using a screwdriver -arrow- and detach cover

-1- for electronics box in engine compartment upwards.

insulation.
– Release and pull off electrical connector on starter ⇒ Elec‐
trical system; Rep. gr. 27; Starter; Removing and installing
starter.
– Unscrew B+ wire from starter solenoid switch ⇒ Electrical
system; Rep. gr. 27; Starter; Removing and installing starter.
– Remove earth wire from body.
Manual gearbox
– Release and pull off electrical connector from gearbox
⇒ Rep. gr. 34; Removing and installing gearbox.
mechanism.


Dual clutch gearbox
page 407 .
illustration.
Vehicles with air conditioner:

129 .
– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side.
– Do NOT stretch, kink or bend refrigerant lines and hoses
while doing so.
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
Vehicles with all-wheel drive:

– Remove propshaft from bevel box ⇒ Rep. gr. 39; Propshaft;
Removing and installing propshaft.
– Remove bracket for bevel box ⇒ Rep. gr. 34; Bevel box;
Assembly overview - bevel box.
– Remove bevel box ⇒ Rep. gr. 34; Bevel box; Removing
bevel box.

– Release and pull off connector -1- on oil level and oil tem‐
– Remove bolt -1- and nuts -arrows- and tie up catalytic con‐
verter.
– Unscrew nuts for coupling rod -arrow- on left and right of

anti-roll bar.


– Unscrew nuts -arrows- for swivel joint on left and right.
– Detach swivel joint from transverse link on left and right.

– If fitted, remove nut -arrow- from front left vehicle level send‐
er -G78-.
– Unbolt drive shaft from gearbox on left and right, and tie it
up ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Assembly overview - drive shaft.
Note
Make sure not to damage the surface protection of the drive

shaft.


and nut -1-.

– If present, raise retaining clip -arrow-. Remove upper right

coolant hose from water radiator for charge air cooling cir‐
cuit.


hoses -arrows-.

Vehicles with engine preheating element -Z97-
– Unclip locking mechanism -arrow-.

– Pull off wiring -1- on engine preheating element -Z97- -2-.
– Unclip all cable ties from wiring harness -1- on engine. Se‐
cure wiring harness to side of vehicle.
– Pull off lower coolant hose on engine preheating element
-Z97-, and remove coolant pipe.
– Unscrew nuts -arrows- and remove engine preheating ele‐
ment -Z97- with bracket.
Note
♦ Place a cloth underneath to catch escaping coolant.

♦ Release hose clip -1- and pull off coolant hose.

Vehicles with 3 gearbox securing bolts:

turns.

turns.

– Position clamping piece -T10497/2- on housing rib of cylin‐

der block as shown in illustration.
– Position engine bracket -T10497- with pin -T10497/1- on
cylinder block.
– Screw in bolt -1- through hole “B” in engine support -
T10497- and tighten to 20 Nm.
– Insert engine and gearbox jack -V.A.G 1383 A- in engine

support -T10497- and raise engine/gearbox assembly slight‐
ly.
Note




Note
♦ Risk of damage to the vacuum lines or electrical wiring as

well as damage to the engine compartment.
♦ Check that all vacuum lines and electrical wiring between
♦ When lowering, carefully guide engine/gearbox assembly


1.2 Separating engine and gearbox

♦ Shackle -10 - 222 A /12-
♦ Hook -10 - 222 A /2-
♦ Workshop hoist -VAS 6100-
• Engine/gearbox assembly removed and attached to engine
support T10497.
– Remove starter ⇒ Electrical system; Rep. gr. 27; Starter;
Removing and installing starter.
– Bolt shackle -10 - 222 A /12- to gearbox.

– Attach workshop hoist -VAS 6100- with hook -10 - 222 A /2-
to shackle -10 - 222 A /12-.
– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.
– Pull gearbox off engine.
1.3 Securing engine on engine and gear‐

box support
♦ Engine and gearbox support -VAS 6095-

♦ Workshop hoist -VAS 6100-
• Gearbox detached from engine ⇒ e1.2 ngine and gearbox”,
page 60 .
– Secure lifting tackle -2024 A- on engine, and attach it to
workshop hoist -VAS 6100- as shown in illustration.
– In order to match the lifting tackle to the centre of gravity of

the engine, the holes in the hook rail must be allocated as
shown in the illustration.
– The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.
Note
Avoid any risk of accident caused by loose components of the

lifting tackle.
– Lift engine off T10497 using workshop hoist -VAS 6100-.

– Secure engine to engine and gearbox bracket -VAS 6095-
using pins -arrows- as shown in illustration.

1.4 Installing engine

• Engine/gearbox assembly secured to engine support
T10497.
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
– Install intermediate plate ⇒ page 147 .

– If there are no dowel sleeves -A- in the cylinder block for
centring the engine and gearbox, insert new dowel sleeves.
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.

– Install gearbox support.
– Take up engine/gearbox assembly with engine support
T10497.
– Guide engine/gearbox assembly into body.
– Use engine and gearbox jack to properly align assembly
mountings free of stress.

Engine mounting, version 1
– First screw bolts -arrows- for engine mountings into stop by

hand.
Engine mounting, version 2
– First screw bolts -arrows- for engine mountings into stop by

hand.
Vehicles with 2 bolts between gearbox mounting and gearbox
bracket
– First screw bolts -arrows- for gearbox mountings into stop by

hand.
Note
The bolts are tightened to final torque only after adjusting the
assembly mountings ⇒ a2.7 ssembly mountings”, page 118 .


bracket
– First screw bolts -arrows- for gearbox mountings into stop by

hand.
Note
The bolts are tightened to final torque only after adjusting the
assembly mountings ⇒ a2.7 ssembly mountings”, page 118 .

– Detach engine support T10497 from engine.
– Install starter ⇒ Electrical system; Rep. gr. 27; Starter; As‐
sembly overview - starter.
– Install air pipe ⇒ o2.1 verview - charge air system”, page
433 .
– Installing air ducts ⇒ o2.1 verview - charge air system”, page
433 .
Vehicles with manual gearbox
– Install clutch slave cylinder ⇒ Rep. gr. 30; Clutch mecha‐
– Install cables with cable support bracket ⇒ Rep. gr. 34; Se‐
lector mechanism; Assembly overview - selector cables.
Vehicles with dual clutch gearbox
– Install selector lever cable, fit connector of mechatronic and
install all retainers on gearbox:⇒ Rep. gr. 34; Removing and
installing gearbox
– Install catalytic converter ⇒ a2.2 nd installing catalytic con‐
verter”, page 570 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40; Drive shaft; Assembly overview - drive shaft.
– Install transverse link, swivel joint and coupling rod ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40; Lower transverse
link, swivel joint; Assembly overview - lower transverse link,
swivel joint.
– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Removing and
installing air conditioner compressor.
– Install poly V-belt ⇒ a1.3 nd installing poly-V belt”, page
129 .

– ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carri‐

ers, electronics boxes; Overview of fitting locations - relay
carriers, fuse carriers, electronics boxes
– ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
– Install engine control unit -J623- ⇒ c6 ontrol unit”, page 495 .
– Connect coolant hoses with plug-in connector ⇒ page 388 .
– Install pendulum support ⇒ a2.4 nd installing pendulum sup‐
port”, page 87 .
Tiguan
– If present, install cross piece ⇒ General body repairs, exteri‐
or; Rep. gr. 66.
– Install left and right front wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66; Wheel housing liners; Assem‐
bly overview - front wheel housing liner.
– Install front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44; Wheels, tyres; Changing wheel.
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
– Adjust assembly mountings ⇒ a2.7 ssembly mountings”,
page 118 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery tray.
– Install air filter housing ⇒ a3.2 nd installing air filter housing”,
page 472 .
– Add coolant ⇒ page 343 .
Note
♦ Drained-off coolant may only be used again if the cylinder

head and cylinder block have not been renewed.
♦ Soiled coolant must not be reused.
If a new base engine has been installed:

• Depending on the version and the variant of the engine
control unit, there may be differences in the availability of
functions.
• Only the functions that are supported by the respective en‐
gine control unit must be performed.
– Perform the function 0001 - Adaption after sender re-
placement ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Reset learnt injector
values ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Adapt / adjust charge
pressure positioner -V465- ⇒ Vehicle diagnostic tester.
– Perform the function 0001 - Adaption of lambda probes
⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 68

♦ Securing gearbox to engine ⇒ Rep. gr. 34; Removing and

installing gearbox; Installing gearbox
Bolted connection Specified tor‐
que
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm

2 Assembly mountings
⇒ o2.1 verview - assembly mountings”, page 68
⇒ a2.2 nd installing engine mounting”, page 80
⇒ a2.3 nd installing gearbox mountings”, page 85
⇒ a2.4 nd installing pendulum support”, page 87
⇒ e2.5 ngine in installation position”, page 89
⇒ a2.6 djustment of assembly mountings (engine and gearbox
mountings)”, page 117
⇒ a2.7 ssembly mountings”, page 118
2.1 Assembly overview - assembly mount‐

ings
⇒ o2.1.1 verview - assembly mountings, Golf Cabriolet, Sciroc‐
co and CC”, page 68
⇒ o2.1.2 verview - assembly mountings, Sharan and Tiguan”,
page 71
⇒ o2.1.3 verview – assembly mountings, T-Roc”, page 74
⇒ o2.1.4 verview – assembly mountings, Golf 2020, Golf Estate
2021”, page 77
2.1.1 Assembly overview - assembly mountings, Golf Cabriolet, Scirocco and

CC

1 - Connection
2 - Bolt
❑ Connection to engine
mounting and body
❑ Renew after removal
❑ 20 Nm +90°
3 - Bolt
❑ Connection to engine
mounting and body
❑ 20 Nm +90°
4 - Bolts
❑ Engine mounting to en‐
gine support
❑ 60 Nm +90°
5 - Bolt
❑ For bracket for activa‐
ted charcoal filter
❑ 20 Nm +90°
6 - Centre hex stud
❑ Engine mounting to
body
❑ 40 Nm +90°
7 - Bolt
body
❑ 40 Nm +90°
8 - Engine mounting
❑ Removing and installing ⇒ a2.2 nd installing engine mounting”, page 80
9 - Bracket
❑ For activated charcoal filter
10 - Bolt
❑ Engine support to engine
❑ Specified torque: ⇒ page 70
11 - Engine support
❑ Removing and installing ⇒ a1.6 nd installing engine support”, page 136
❑ Tightening sequence ⇒ Fig. ““Engine support - specified torque and installation sequence”“, page 70
12 - Bolt
❑ Gearbox mounting to gearbox support
❑ 60 Nm +90°
13 - Bolt
❑ Gearbox mounting to body
2. Assembly mountings 69
❑ 40 Nm +90°
14 - Gearbox mounting
❑ Illustration shows version for dual clutch gearbox.
15 - Bolt
❑ Gearbox support to gearbox
Specified torques
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34; Removing and installing gearbox; Specified torques
for gearbox
16 - Centre hex stud
❑ Gearbox support to gearbox
Specified torques
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with dual clutch gearbox ⇒ Rep. gr. 34; Removing and installing gearbox; Specified torques
for gearbox
17 - Rear final drive support
18 - Pendulum support
❑ Removing and installing ⇒ page 71
❑ Bolt pendulum support to gearbox and then to subframe.
19 - Bolt
❑ Pendulum support to sub-frame
20 - Bolts
❑ Pendulum support to gearbox
Engine support - specified torque and installation sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in stages in the sequence -1 … 3-.

Stage Bolts Specified torque/turning further angle

1st -1 … 3- 7 Nm
2nd -1 … 3- 40 Nm
3rd -1 … 3- Turn 90° further
Tightening sequence for pendulum support
– Renew bolts that are tightened with specified tightening an‐

gle.
– Tighten bolts in stages in the sequence shown.
1st -2, 3- 50 Nm
2nd -1- 130 Nm
2.1.2 Assembly overview - assembly mountings, Sharan and Tiguan
1 - Bolt
❑ 20 Nm +90°
2 - Bolt
body
❑ 40 Nm +90°
3 - Engine mounting
❑ Removing and instal‐
ling ⇒ a2.2 nd installing
engine mounting”, page
80
4 - Bolt
body
❑ 40 Nm +90°
5 - Bolts
gine support
❑ 60 Nm +90°
ling ⇒ a2.4 nd instal‐
ling pendulum support”,
page 87
❑ Tightening sequence ⇒
page 73
7 - Bolt
❑ Pendulum support to subframe ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly
overview - subframe
❑ ⇒ Fig. ““Tightening sequence for pendulum support”“, page 73
❑ 100 Nm +90°
8 - Bolt
❑ 50 Nm +90°
9 - Bolt
❑ 50 Nm +90°
10 - Bolts
❑ Gearbox mounting to gearbox

❑ 60 Nm +90°
11 - Bolts
❑ 40 Nm +90°
❑ Illustration shows version for dual clutch gearbox.
❑ Removing and installing ⇒ a2.3 nd installing gearbox mountings”, page 85
13 - Engine support
❑ Tightening sequence ⇒ page 73
14 - Bolts
Note

1st -1 … 3- 7 Nm
2nd -1 … 3- 40 Nm
Tightening sequence for pendulum support

gle.
1st -2, 3- 50 Nm
2nd -1- 100 Nm
2.1.3 Assembly overview – assembly mountings, T-Roc

1 - Bolt
body
❑ 40 Nm +90°
2 - Bolts
gine support
❑ 60 Nm +90°
3 - Engine mounting
80
4 - Engine support
engine support”, page
136
❑ Tightening sequence ⇒
page 76
5 - Bolts
❑ Gearbox mounting to
gearbox
❑ 60 Nm +90°
6 - Bolts
❑ 50 Nm +90°
❑ Removing and installing ⇒ a2.3 nd installing gearbox mountings”, page 85
8 - Bolt
❑ Do not loosen
9 - Bolt
❑ Pendulum support to subframe ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly
overview - subframe
❑ ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“, page 76
❑ 130 Nm +90°
10 - Bolt
❑ 60 Nm +90°
11 - Bolt
❑ 60 Nm +90°
❑ Removing and installing ⇒ a2.4 nd installing pendulum support”, page 87
❑ Tightening sequence ⇒ Fig. ““Pendulum support - specified torque and tightening sequence”“, page
76
13 - Nut
❑ Do not loosen
14 - Bolt
15 - Bolt
16 - Bolt
17 - Bolt
❑ 25 Nm +90°
Note

1st -1 … 3- 7 Nm
2nd -1 … 3- 40 Nm
Pendulum support - specified torque and tightening sequence

Note
Renew bolts that are tightened with turning further angle after
each removal.

1st -2, 3- 60 Nm
2nd -1- 130 Nm
2.1.4 Assembly overview – assembly mountings, Golf 2020, Golf Estate 2021
1 - Engine mounting
80
2 - Bolt
❑ 25 Nm +90°
3 - Bolt
body
❑ 40 Nm +90°
4 - Nut
❑ 9 Nm
5 - Earth strap
6 - Hanger bolt
❑ 60 Nm +90°
7 - Bolt
❑ 60 Nm +90°
• Only vehicles with manual
gearbox
9 - Bolt
❑ Renew
❑ 60 Nm +90°
10 - Bolt
❑ 40 Nm +90°
11 - Bolt
❑ 60 Nm +90°
12 - Bolt
❑ 40 Nm +90°
• Only vehicles with dual clutch gearbox or automatic gearbox
❑ Removing and installing ⇒ a2.4 nd installing pendulum support”, page 87
15 - Bolt
❑ 130 Nm +90°
16 - Bolt

❑ 60 Nm +90°
17 - Bolt
❑ 60 Nm +90°
18 - Engine support
19 - Bolt
Note

1st -1 … 3- 7 Nm
2nd -1 … 3- 40 Nm
Pendulum support - specified torque and tightening sequence
Note
Renew bolts that are tightened with turning further angle after
each removal.

1st -2, 3- 60 Nm
2nd -1- 130 Nm
2.2 Removing and installing engine mount‐

ing
⇒ a2.2.1 nd installing engine mounting, Golf Cabriolet, Scirocco
and CC”, page 80
⇒ a2.2.2 nd installing engine mountings, Sharan and Tiguan”,
page 82
⇒ a2.2.3 nd installing engine mounting, T-Roc”, page 83
⇒ a2.2.4 nd installing engine mounting, Golf 2020, Golf Estate
2021”, page 84
2.2.1 Removing and installing engine mount‐

ing, Golf Cabriolet, Scirocco and CC
Removing

– Release locking lug -3- in direction of arrow, and remove
activated charcoal filter -1- upwards.

– Place activated charcoal filter -1- with breather line -arrow-

and line -2- on engine.
tank -1-.
– Support engine in its installation position ⇒ e2.5 ngine in
installation position”, page 89 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -5-, and remove bracket -4-.
– Unscrew bolts -1- and -3-, and remove engine mounting -2-
upwards.
Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ a2.6 djust‐

ment of assembly mountings (engine and gearbox mount‐
ings)”, page 117 .
Specified torques

ings, Sharan and Tiguan
Removing
bracket -d-.
– Unscrew bolts -arrows- and remove engine mounting -1-.
Installing
Specified torques


ing, T-Roc
♦ Torque wrench (20-100 Nm) -VAS 5820A- (not illustrated)
Removing

– Use a screwdriver to release catch -arrow-, and place cool‐
ant expansion tank on engine.
– If fitted, remove vacuum pump for brakes -V192- ⇒ Brake
system; Rep. gr. 47; Vacuum system; Removing and instal‐
ling electric vacuum pump (for brakes).
Installing
Specified torques

ing, Golf 2020, Golf Estate 2021
Removing
– Open bracket -3-, detach fuel hoses -2- from bracket.

– Using a screwdriver, release fasteners in direction of -arrow-
and lay coolant expansion tank to one side.
– Unscrew nuts -1- and -2-, remove earth wire.
– Support engine in installation position. ⇒ e2.5 ngine in instal‐

lation position”, page 89

Installing
Note
♦ If specified torque and tightening sequence are not adhered

to, used bolts may become loose.
Install in reverse order of removal.

Specified torques
2.3 Removing and installing gearbox

mountings
Removing
– Remove resonator for intake air ⇒ a3.4 nd installing resona‐
tor for intake air”, page 476 .
ing”, page 472 .
– Remove engine control unit.
– Unscrew nuts -arrows- and remove bracket -1-.
Note
Different types of brackets are fitted depending on version.
– Unclip wire guide -1- upwards -arrows-, and push it slightly

to one side.

bracket:
– Remove bolts -arrows- and detach gearbox mounting -1-.

bracket:
– Remove bolts -arrows- and detach gearbox mounting -1-.

Installing


gle.
– Tighten gearbox mounting on longitudinal member.
– Lift gearbox with spindle of support bracket until gearbox
support makes contact with support arm of gearbox mount‐
ing.
– Gearbox support and support arm of gearbox mounting must
be perfectly parallel to each other before screwing in bolts. If
necessary, lift gearbox at rear using trolley jack.
– Start bolts by hand. Ensure to not screw in the bolts at an
angle while doing so.
– First screw in bolts for gearbox mounting to stop by hand.
– When the bolts are tightened to specified torque, remove
support bracket -10 - 222 A- from engine.
Specified torques
♦ ⇒ o3.1 verview - air filter housing”, page 470
♦ ⇒ Electrical system; Rep. gr. 27; Battery; Assembly overview
- battery
2.4 Removing and installing pendulum

support
♦ Torque wrench -V.A.G 1331-
Removing
insulation.
– First unscrew bolt -1-.
– Then remove bolts -2- and -3-.

– Remove pendulum support -4- from subframe -5-.
Installing
Note
There are threaded inserts, e.g. “Heli-Coil” in the bolting holes

for the pendulum support.
The shoulder on the first thread pitch -arrow- is an identifying

feature.
Specified torques

2.5 Supporting engine in installation posi‐

tion
⇒ e2.5.1 ngine in installation position, Golf Cabriolet”, page 89
⇒ e2.5.2 ngine in installation position, Tiguan”, page 93
⇒ e2.5.3 ngine in installation position, Sharan”, page 97
⇒ e2.5.4 ngine in installation position, CC”, page 101
⇒ e2.5.5 ngine in installation position, Scirocco”, page 103
⇒ e2.5.6 ngine in installation position, T-Roc”, page 107
⇒ e2.5.7 ngine in installation position, Golf 2020, Golf Estate
2021”, page 111
2.5.1 Supporting engine in installation posi‐

tion, Golf Cabriolet
♦ Square tube and 2 wing bolts from support bracket -10 - 222
A-
♦ Spindles -10-222A-
♦ Square tube -T40091/1-
♦ Joints -T40091/3-
♦ Adapter -10-222A/13-
♦ Adapter -10-222A/28-
♦ Adapter -10-222A/28-2-
♦ Shackle -10 - 222 A /12-
♦ Spacer tube -10-222A/17-


ing”, page 472 .
– Remove foam sections or seals from upper edge of left and
right wings ⇒ General body repairs, exterior; Rep. gr. 50;
Wings; Assembly overview - wings.
– Unscrew bolts -arrows- for retaining brackets on left and
right of lock carrier.
– Unscrew lower mounting from adapter -10 - 222 A /28-.
– Screw in adapter -10-222 A /28-2-.

– Unscrew one securing bolt -arrow- from adapter -10-222 A /
28-2-.
– Bolt adapter -10-222 A /28-2- to lock carrier using securing
bolt -1-.
– The adapter -10-222A/13- must be positioned as shown in

the illustration. The panel edge -arrow- must not be bent.
– Insert spacer tube -10-222A/17- between handle and spindle

-10-222A- support as shown.
– Slide adapter -T40091/3- and spindle -10-222A- onto square

section tube of support bracket -10 - 222 A- as shown.
– Bolt square section tube of support bracket -10 - 222 A- to
adapter -10-222A/13-
– Push square section tube -T40091/1- into adapter -10 - 222
A /28- on left side.
– Push square section tube -T40091/1- into adapter -
T40091/3- on left side.

– Push square section tube -T40091/1- into adapter -10 - 222

A /28- on right side.
– Push square section tube -T40091/1- into adapter -
T40091/3- on right side.
– Screw shackles -10 - 222 A /12- onto support eyes on left
and right sides.
– Hookspindle -10-222A- onto shackle -10 - 222 A /12- on
right side.
– Attach spindle -10-222A- to shackle -10 - 222 A /12- on left
side.
– Tighten all threaded connections of support bracket hand-
tight.
– Align support bracket.
– Tighten all threaded connections of support bracket.
WARNING
Risk of injury due to improper handling of the support bracket.
Improper handling can lead to damage of the tool and subse‐
quent injuries.
– Never loosen and dismantle the engine and gearbox
mountings at the same time to avoid overloading of the
support bracket.

tion, Tiguan
♦ Adapter -10 - 222 A /18-
♦ Adapter -10 - 222 A /28-
♦ Adapter -10 - 222 A /32-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Rack -10 - 222 A /1-

♦ Support bracket -10 - 222 A-
♦ Swivel joint -T40091/3-

ing”, page 472 .
– Prepare support bracket as shown in illustration, and fit it
onto edges of wings.
– Loosen 3 bolts -arrows- of trim -1-.
– Unscrew bolt -1- on left of lock carrier.
– Unscrew lower mounting from adapter -10 - 222 A /28- and

replace with adapter -10-222 A /28-2-.

28-2-.
bolt -1-.

– Slide square section tube -T40091/1- through adapter -10 -

222 A /28- and rotary joint -T40091/3-.
– Fit engine support bracket -10 - 222 A- as shown in illustra‐
tion.

tight.
WARNING
quent injuries.
support bracket.

tion, Sharan
♦ Adapter -10 - 222 A /8-

♦ Support -T40093/3-

♦ Foot -T40093/3-5-
♦ Shackle -10 - 222 A /12-
Setting up support bracket:

– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Plenum chamber bulkhead; Removing
and installing plenum chamber cover.
– Remove radiator grille ⇒ General body repairs, exterior;
Rep. gr. 66; Radiator grille/front trim; Assembly overview -
radiator grille.
– Push articulated joint -T40091/3- onto square tube of sup‐
port bracket -10 - 222 A-.
– Push spindles of support bracket -10 - 222 A- onto square

tube to left and right of articulated joint -T40091/3-.
– Spindles are located in front of square tube in direction of
travel.
Note
Disregard adapter -10 - 222 A /3-.
– Fit adapter -10 - 222 A /8- as shown, and bolt it to square

tube.
• Rubber blocks -A- are pointing outwards.
• Set up support bracket -10-222 A- behind bonnet support.

– Screw foot -T40093/3-5- into support -T40093/3-.
– Push support -T40093/3- onto square tube -T40091/1-.
– Fit adapter -T40093/3- with foot -T40093/3-5- onto bumper

carrier -A-.

– Push square tube -T40091/1- into rotary joint -T40091/3-.

– Align support bracket and tighten all bolts hand-tight.
– Insert hooks of spindles with shackles -10 - 222 A /12- into
engine lifting eyes on both sides.
– Support engine in installation position.
WARNING
quent injuries.
support bracket.

tion, CC
Support bracket -10 - 222 A-
♦ Adapter -10 - 222 A /1-

♦ Adapter -10-222 A /3-
♦ Hook -10 - 222 A /10-
♦ Adapter -10 - 222 A /18- (longer tube points towards front
end)
♦ Shackle -10-222 A /12-
Setting up support bracket
– Remove filler pieces from upper edges of both wings.
– If there are hose and cable connections in area of engine
support eyes for support bracket -10-222A-, remove these
now.
– Set up support bracket -10-222 A- in front of bonnet stay.

– Position adapter -10 - 222 A /1- as follows.

• On upper longitudinal members
• Directly next to plenum chamber cover
• Behind bolts -arrow 1- and -arrow 2-.
• Do not place the adapters -10-222 A /1- on the bolt-on plates
of the wings. These may otherwise be damaged.
The surface of the two upper longitudinal members is different.
Therefore, the adapters -10 - 222 A /1- do not rest against them
over the entire contact surface.
– Connect bracket -T10346- or -T10346/1- via shackle -10-222
A /12- to support bracket.
– Attach spindles in engine support eyes.
– If necessary, use shackle (-1-).

-1- = shackle -10 - 222 A /12-
– Take up weight of engine/gearbox assembly and support
bracket on spindles.

WARNING
quent injuries.
support bracket.

tion, Scirocco
♦ Adapter -10 - 222 A /18-
♦ Adapter -10 - 222 A /28-
♦ Adapter -10 - 222 A /32-

♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Rack -10 - 222 A /1-


ing”, page 472 .
– Move clear hose -2- from activated charcoal filter.
– Using a screwdriver, release fasteners -arrow- and move

coolant expansion tank to one side.
– Unscrew bolt -1- on left of lock carrier.
– Unscrew lower mounting from adapter -10 - 222 A /28- and

replace with adapter -10-222 A /28-2-.


28-2-.
bolt -1-.
– Slide square section tube -T40091/1- through adapter -10 -

222 A /28- and rotary joint -T40091/3-.
tion.


tight.
WARNING
quent injuries.
support bracket.

tion, T-Roc
♦ Shackle -10 - 222 A /12-
♦ Adapter -10-222A/3-

♦ Adapter -10-222A/35-
♦ Hook -10-222A/10-
♦ Tube -T40091/1-
♦ Support joint -T40091/3-

♦ Support -T40093/3P- (not illustrated)
♦ Adapter -T40093/3-6A- (not shown)
♦ Release tool -T10236-

Preparing support bracket -10 - 222 A-:
– If support bracket -10 - 222 A- does not yet have a hole

(marked with -arrow-), drill it into support bracket according‐
ly.
• Dimension -a- = 225 mm.
• Hole ∅ = 12.5 mm.
Procedure
Note
The securing bolts of the assembly mountings may only be

loosened if the engine is supported in installation position using
the support bracket -10-222 A-.

ing”, page 472 .
– Unclip wires -arrows- in front area of longitudinal member on
left side. Use release tool -T10236- for this.
– Release and pull off electrical connectors -1- and -2-.

– Release electrical connector on bracket and unclip.

– Open locking element on bracket -arrow- on longitudinal
member.
– Expose wiring harness leading to engine control unit on
bracket.
– Expose positive wire leading to fuse carrier on bracket.
– Unclip wiring harness leading to engine control unit from
bracket and battery tray. Use release tool -T10236- for this.
– If necessary, release and pull off wiring harness on engine
control unit ⇒ a6.3.3 nd installing engine control unitJ623
with protective housing, T-Roc”, page 512 .
– Move aside wiring harnesses.
– Unclip bracket on longitudinal member using release tool
-T10236-, and swivel it to right.
Note
Make sure that neither the lines nor the bracket become trap‐
ped or damaged.
Setting up support bracket:

Assemble engine support bracket -10-222 A- as shown:

A - Adapter -10-222A/35-
B - Square tube of support bracket -10-222 A-
C - Adapter -10-222A/3-
D - Hook -10-222A/10-
E - Support -T40091/3-
F - Tube -T40091/1-
G - Support -T40093/3P-
H - Adapter -T40093/3-6A-
I - Shackle -10 - 222 A /12-
– Bolt adapter-T40093/3-6A- -item H- to support -T40093/3P-
-item G-, and fit it to left longitudinal member as shown in
illustration.
– Position adapter -T40093/3-6A- -item H- next to filler tube for
washer fluid reservoir.
• Adapter -T40093/3-6A- -item H- must engage with pin be‐
hind web of longitudinal member -arrow-.
– If necessary, push adapter -T40093/3-6A- -item H- into cor‐
rect position.
– Align support bracket.
– Tighten all threaded connections of support bracket.
– Tighten hooks -10-222A/10- slightly to take up weight of
engine/gearbox assembly; do not lift.
WARNING
quent injuries.
support bracket.

tion, Golf 2020, Golf Estate 2021
♦ Shackle -10 - 222 A /12-

♦ Adapter -10 - 222 A /18-

♦ Adapter -10 - 222 A /29-
♦ Adapter -T40091/1-
♦ Adapter -T40093/3-6-

Check adapters -T40093/3-6- and modify as necessary
– If necessary, cut off the marked area.

– Round off front edges.
– Protect adapter against corrosion.
– Then, mark adapters -T40093/3-6- as -T40093/3-6A-.
At a later point, support bracket -10-222 A- will be fitted onto
longitudinal members with adapters -T40093/3-6A-.
• To prevent damage to the longitudinal members, wrap the
front section of the adapters -T40093/3-6A- with textile-rein‐
forced adhesive tape ⇒ Electronic parts catalogue (ETKA
chemical substances).
tor for intake air”, page 476
ing”, page 472 .
– Open bracket -3-, detach fuel hoses -2- from bracket.

– Using a screwdriver, release fasteners in direction of -arrow-
and lay coolant expansion tank to one side.
– Screw adapter -T40093/3-6A- to support -T40093/3- and fit
on right longitudinal member.

– If fitted, pull off electrical lines in front area of web on right

longitudinal member -arrow-. Do not disconnect pipe/hose
system.
– Unclip refrigerant line from retainer.
– Place adapter-T40093/3-6A- onto right longitudinal member.
• The adapter-T40093/3-6A- is locked with the pin -A- behind
the flange of the longitudinal member -arrow-.
– Unclip wires -arrows- in front area of longitudinal member on
left side. Use release tool -T10236- for this.
– Release and pull off connectors -1- and -2-.

– Release connector on retainer and unclip.

– Open locking element on retainer -arrow- on longitudinal
member.
– Expose wiring harness for engine control unit on bracket.
– Expose positive wire for fuse carrier on bracket.
– Unclip wiring harness leading to engine control unit from
bracket and on battery tray. Use release tool -T10236- for
this.
– If necessary, release and pull off wiring harness on engine
control unit ⇒ c6 ontrol unit”, page 495 .
– Lay wiring harnesses aside.
– Use release tool -T10236- to unclip bracket on longitudinal
member and swivel to right.
– Remove filler neck -1- at top on lock carrier -2-.
– To do this, release locking lug -3- in direction of -arrow-.

– Pull filler neck -1- upwards out of mounting.
– Screw adapter -T40093/3-6A- to -A- support -T40093/3- and
fit on left longitudinal member.

– Guide adapter -T40093/3-6A- below filler pipe of washer flu‐

id reservoir.
– Place adapter -T40093/3-6A- onto left longitudinal member.
– Adapter -T40093/3-6A- must engage with pin -A- behind
web of longitudinal member -arrow-.
– If necessary, push adapter -T40093/3-6A- into correct posi‐
tion.
– Note lines and retainers.
Installation position of adapters -10 - 222 A /29-:
♦ “L” = -1- adapter is used on “right-hand” side of vehicle.

♦ “R” adapter is inserted on “left” side of vehicle.
♦ On both sides of vehicle, insert adapters -10 - 222 A /29-
between wing mounting flange and sheet metal for mounting
wing underneath it.
tion.


WARNING
quent injuries.
support bracket.
2.6 Checking adjustment of assembly

mountings (engine and gearbox
mountings)
bracket -d-.
• There must be a distance -a- of 10 to 13 mm between en‐
gine support and right longitudinal member.

• The cast edge on the engine support -a- must be aligned

parallel to support arm.
• Dimension -b- must be identical at front and rear.
– If there is a noise problem and dimension -a- is outside the
tolerance range, adjust assembly mountings ⇒ a2.7 ssembly
mountings”, page 118 .
2.7 Adjusting assembly mountings

bracket -d-.
– Unscrew engine mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐
gine).

– First screw bolts in loosely.

bracket:

bracket:
– Unscrew gearbox mounting bolts -arrows- one after the oth‐

er, and renew them (if not already renewed when installing
engine).
– Initially, screw in bolts -arrows- for gearbox mountings to
stop by hand.

– Using assembly lever, adjust engine/gearbox assembly until

specifications listed below are attained:
• There must be a distance -a- = 10 mm between engine
support and engine mounting.
• Side surface of the engine support casting should be located
parallel to support arm of engine mounting.
• Dimension -b- must be identical on both sides.
– Tighten bolts for engine mounting.
Note
Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.
– Tighten bolts for engine mounting.

bracket:
– On the gearbox side, ensure that the edges of the support

arm -2- and gearbox support -1- are parallel.
• Distance -x- = distance -x-.


bracket:
– On the gearbox side, ensure that the edges of the support

arm -2- and gearbox support -1- are parallel.
• Distance -x- = distance -x-.
– Tighten bolts for gearbox mounting.
Specified torques
♦ ⇒ o2.1 verview - charge air system”, page 433
- battery

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ o1.1 verview - poly V-belt drive”, page 122
⇒ o1.2 verview - sealing flange, belt pulley end”, page 126
⇒ a1.3 nd installing poly-V belt”, page 129
⇒ a1.4 nd installing tensioner for poly V-belt”, page 133
⇒ a1.5 nd installing vibration damper”, page 134
⇒ a1.6 nd installing engine support”, page 136
⇒ c1.7 rankshaft oil seal - belt pulley end”, page 139
⇒ a1.8 nd installing sealing flange on pulley end”, page 142
1.1 Assembly overview - poly V-belt drive

⇒ o1.1.1 verview - poly V-belt drive, vehicles without air condi‐
tioner compressor”, page 122
⇒ o1.1.2 verview - poly V-belt drive, vehicles with air conditioner
compressor”, page 124
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner
compressor
122 Rep. gr.13 - Crankshaft group

1 - Bolt
❑ Use counter-hold tool -
T10475- to loosen and
tighten
❑ 150 Nm +180°
2 - Vibration damper
vibration damper”, page
134
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
❑ Do not kink
❑ Poly V-belt routing ⇒
page 130
poly-V belt”, page 129
❑ When installing, make
sure it is properly seat‐
ed on pulleys.
4 - Bolt
❑ 20 Nm +90°
5 - Tensioning device for poly
V-belt
❑ Pivot with socket to
slacken poly V-belt
❑ Lock with locking pin -
T10060 A-.
❑ Removing and installing ⇒ a1.4 nd installing tensioner for poly V-belt”, page 133
6 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27; Alternator; Removing and installing alterna‐
tor
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type
and version of alternator ⇒ page 123 .
Allocation of overrunning alternator pulley
1. Cylinder block (pulley end) 123

For allocation, refer to ⇒ Electronic parts catalogue
1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor

1 - Poly V-belt
❑ Check for wear
direction of rotation with
chalk or felt-tipped pen
❑ Do not kink
❑ Poly V-belt routing ⇒
page 132
ling ⇒ a1.3.1 nd in‐
stalling poly V-belt, ve‐
hicles without air con‐
ditioner compressor”,
page 129
❑ When installing, make
sure it is properly seat‐
ed on pulleys.
2 - Bolt
❑ Specified torque ⇒ Item
1 (page 123)
134
4 - Tensioning device for poly
V-belt
❑ Pivot with socket to
slacken poly V-belt
❑ Lock with locking pin -
T10060 A-.
ling tensioner for poly
V-belt”, page 133
5 - Bolt Volkswagen Technical Site: https://vwts.ru
❑ 20 Nm +90°
6 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27; Alternator; Removing and installing alterna‐
tor
❑ With freewheel
❑ Various versions of the overrunning alternator pulley, -A- or -B-, may be fitted depending on the type
and version of alternator ⇒ page 126 .
8 - Dowel sleeve
❑ For air conditioner compressor
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87; Air conditioner compressor;
Removing and installing air conditioner compressor from and to bracket
10 - Bolt

❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
Allocation of overrunning alternator pulley
1.2 Assembly overview - sealing flange, belt pulley end

1 - Bolt
❑ Specified torque ⇒ Item
1 (page 123)
134
3 - Seal
❑ For crankshaft on belt
pulley end
❑ Renewing ⇒ c1.7 rank‐
shaft oil seal - belt pul‐
ley end”, page 139
❑ Do not oil
4 - Sealing flange at belt pul‐
ley end
❑ Must seat on dowel
pins.
sealing flange on pulley
end”, page 142
5 - Bolt
❑ Different thread diame‐
ters ⇒ Electronic parts
catalogue
❑ Specified torque and
tightening sequence ⇒
page 127
6 - Seal
7 - Cylinder block
8 - Dowel pin
❑ Qty. 2
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 127
Sealing flange at belt pulley end - Prescribed torque and tight‐

ening sequence

Note
– Tighten bolts -1 … 12- in stages:

Stage Bolts Specified torques/angle specifica‐
tions
1st -1 … 12- Screw onto stop by hand
2nd -1 … 12- 8 Nm
3rd -7, 8- 20 Nm
4th -1 … 12- turn 90° further diagonally
Plug for “TDC” drilling in cylinder block at rear – specified torque
Note
♦ Plug with integrated seal -arrow-

♦ Renew if damaged
Bolt Specified torque

-Arrow- 30 Nm

1.3 Removing and installing poly-V belt

⇒ a1.3.1 nd installing poly V-belt, vehicles without air condition‐
er compressor”, page 129
⇒ a1.3.2 nd installing poly V-belt, vehicles with air conditioner
compressor”, page 131
1.3.1 Removing and installing poly V-belt,

vehicles without air conditioner com‐
pressor
Removing
– To slacken poly V-belt, turn tensioner anti-clockwise in
-direction of arrow-.
– Lock tensioning device in place with locking pin -T10060 A-.

– If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.
– Remove poly V-belt.
Installing
Various versions of the overrunning alternator pulley, -A- or -B-,
may be fitted depending on the type and version of alternator.


– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
– Turn tensioning device in -direction of arrow-, and pull out
locking pin -T10060 A-.
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.

1.3.2 Removing and installing poly V-belt,

vehicles with air conditioner compres‐
sor
Removing
– If poly V-belt is to be reinstalled, mark direction of rotation on
belt using chalk or felt tip pen before removing.
– Fit tool -3- onto hexagon of tensioner -1-.
– To slacken poly V-belt push tool -3- in -direction of arrow-.

– Lock tensioner -1- in place with locking pin -T10060 A- -2-.
– Remove poly V-belt -4-.
Installing
Various versions of the overrunning alternator pulley, -A- or -B-,
may be fitted depending on the type and version of alternator.


– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
– Push tool -3- in -direction of arrow-, and pull out locking pin
-T10060 A- -2-.
– Release tension from tensioner -1-.

– Check that poly V-belt -4- is properly seated.

– Start engine and check that poly V-belt runs properly.
1.4 Removing and installing tensioner for

poly V-belt
⇒ a1.4.1 nd installing tensioner for poly V-belt, vehicles without
air conditioner compressor”, page 133
⇒ a1.4.2 nd installing tensioner for poly V-belt, vehicles with air
conditioner compressor”, page 133
1.4.1 Removing and installing tensioner for

poly V-belt, vehicles without air condi‐
tioner compressor
Removing
– Remove poly V-belt from tensioner ⇒ a1.3.1 nd installing
poly V-belt, vehicles without air conditioner compressor”,
page 129 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
– Install poly V-belt ⇒ a1.3.1 nd installing poly V-belt, vehicles
without air conditioner compressor”, page 129 .
Specified torques
♦ ⇒ o1.1.1 verview - poly V-belt drive, vehicles without air
conditioner compressor”, page 122
1.4.2 Removing and installing tensioner for

poly V-belt, vehicles with air condition‐
er compressor
Removing
– Remove poly V-belt from tensioner ⇒ a1.3.2 nd installing
poly V-belt, vehicles with air conditioner compressor”, page
131 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.

Installing
– Install poly V-belt ⇒ a1.3.2 nd installing poly V-belt, vehicles
with air conditioner compressor”, page 131 .
Specified torques
♦ ⇒ o1.1.2 verview - poly V-belt drive, vehicles with air condi‐
tioner compressor”, page 124
1.5 Removing and installing vibration

damper
♦ Counter-hold tool -T10475-
Preparing counterhold tool -T10475-
Note
♦ Different types of vibration damper can be installed.

♦ For this reason, the counterhold tool -T10475- must be
adapted to the holes of the respective vibration damper.

Version 1
– Convert counterhold tool -T10475- -1- with inserts -

T10475/2- -2-.
Version 2
– Convert counterhold tool -T10475- with inserts -T10475/1-

and -T10475/2- as shown in illustration.
• To do this, use hole -A- or -B- of counterhold tool -T10475-
-1- depending on type of vibration damper.
Removing
insulation.
129 .
– Set crankshaft to »TDC« of cylinder no. 1. ⇒ p4.7 iston to
TDC position”, page 174
– Loosen bolt -arrow- for vibration damper using counterhold
-T10475-.

– Unscrew bolt and remove vibration damper.
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Installing
Note

♦ All contact surfaces between bolt, vibration damper and
crankshaft toothed belt pulley must be free of oil and grease.
– Fit vibration damper, oil threads of bolt for vibration damper

and screw it in to stop by hand.
– Tighten bolt -arrow- for vibration damper using counterhold

-T10475-.
Continue installation in reverse order of removal. Observe the
following when doing this:
– Install poly V-belt ⇒ a1.3 nd installing poly-V belt”, page
129 .
Specified torques
♦ ⇒ o1.1 verview - poly V-belt drive”, page 122
1.6 Removing and installing engine sup‐

port
Removing
Disconnecting and reconnecting battery.
ing”, page 472 .
– Remove tensioner for poly V-belt ⇒ a1.4 nd installing ten‐
sioner for poly V-belt”, page 133 .
– Remove upper toothed belt guard. ⇒ a2.3.1 nd installing
upper toothed belt guard”, page 203


– Unscrew bolt -1-.
– Loosen hose clip -2- and pull off coolant hose.

– Unscrew bolts -1- and remove bracket -2- for catalytic con‐
verter.
– Removing engine mounting ⇒ a2.2 nd installing engine

mounting”, page 80 .
– Loosen bolt -1- but do not remove.

– Swivel alternator -3- in -direction of arrow- towards front.
– Unscrew bolts -arrows- from bracket for front exhaust pipe.


– Unscrew bolts -arrows-.
– Unscrew bolts -1, 2, 3-.

– Push engine/gearbox assembly slightly towards left, and de‐

tach engine support.
Installing
Specified torques
♦ ⇒ o2.1 verview - toothed belt cover”, page 198
♦ ⇒ o3.1 verview - coolant pipes”, page 374
♦ ⇒ o2.1 verview - emission control”, page 568
♦ ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly over‐
view - alternator
- battery
1.7 Renewing crankshaft oil seal - belt pul‐

ley end
♦ Assembly tool -T10485A-
♦ Press tool -T10485/4- (not illustrated)

♦ Extractor hook -T20143-

– Remove toothed belt ⇒ a2.7 nd installing toothed belt”, page
227 .
– Detach crankshaft pulley -1- -arrow-.
NOTICE
– Pry out seal using extractor hook -T20143/2- -arrow-.
– Clean contact surface and sealing surface.
Note
Do not lubricate new seal.
– Fit new seal in -direction of arrow- onto assembly sleeve

-T10485/2-.

– Pull off assembly sleeve -T10485/3- in -direction of arrow-.
• Installation position: closed end of seal faces fitting sleeve.

– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Use fitting sleeve -T10485/4- -2- and pulley bolt -1- to pull in
oil seal -3- onto stop.
– Fit crankshaft sprocket onto crankshaft.

• The contact surface between vibration damper and crank‐

shaft toothed belt pulley must be free of oil and grease.
• The machined surface -arrow- of crankshaft pulley must be
positioned over the machined surface of the crankshaft jour‐
nal.
– Install toothed belt ⇒ a2.7 nd installing toothed belt”, page
227 .
1.8 Removing and installing sealing flange

on pulley end
♦ Scraper
♦ Sealant ⇒ Electronic Parts Catalogue
Removing
insulation.
– Remove air conditioner compressor from bracket, and se‐
cure it on vehicle ⇒ Heating, air conditioning; Rep. gr. 87; Air
conditioner compressor; Removing air conditioner compres‐
sor from and installing to bracket.
– Remove toothed belt ⇒ a2.7 nd installing toothed belt”, page
227 .
NOTICE
– Unscrew bolts -1 to 12- and carefully remove sealing flange

from the glued joint.

– Drive out radial oil seal with sealing flange removed.

Installing
• The lubrication system can be soiled by sealant residue.
• Cover open section of sump with clean clothes.
– Remove sealant residue from sealing flange and sump (top
section).
– Remove any oil and grease from sealing surfaces.
Note
Observe use-by date of sealant.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).
– Slide gasket -1- onto dowel pins in cylinder block.

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
– Thinly coat lower sealing surface -arrow- on sealing flange
with sealant.
Note
Install the sealing flange within 5 minutes after the sealant has
been applied.
– Carefully fit gasket sealing flange onto dowel pins on cylin‐

der block.
– Tighten bolts for sealing flange ⇒ page 127 .
– Fit oil seal for crankshaft at belt pulley end ⇒ c1.7 rankshaft
oil seal - belt pulley end”, page 139 .
– Fit crankshaft sprocket onto crankshaft.
• The contact surface between vibration damper and crank‐

shaft toothed belt pulley must be free of oil and grease.
• The machined surface -arrow- of crankshaft pulley must be
positioned over the machined surface of the crankshaft jour‐
nal.
– Install toothed belt ⇒ a2.7 nd installing toothed belt”, page
227 .
installing air conditioner compressor.
insulation.

Specified torques
♦ ⇒ Fig. ““Sealing flange at belt pulley end - Prescribed torque
and tightening sequence”“, page 127
view - alternator

2 Cylinder block, gearbox end

⇒ o2.1 verview - cylinder block, gearbox end”, page 146
⇒ a2.2 nd installing flywheel”, page 147
⇒ a2.3 nd installing sealing flange on gearbox side”, page 148
2.1 Assembly overview - cylinder block, gearbox end
Note
For assembly work, secure engine to engine and gearbox support ⇒ e1.3 ngine on engine and gearbox
1 - Bolt
❑ 60 Nm +90°
2 - Flywheel
flywheel”, page 147
❑ Can only be fitted in
one position
3 - Engine speed sender -
G28-
ling ⇒ a1.5 nd in‐
stalling engine speed
senderG28”, page 585
4 - Bolt
❑ Specified torque ⇒
o1.1 verview - ignition
system”, page 578
5 - Dowel pin
❑ Qty. 2
6 - Adapter
❑ Do not damage or bend
when assembling.
❑ Installing ⇒ page 147
7 - Bolt
page 146
8 - Sealing flange with sender
wheel and oil seal
❑ Renew sealing flange
complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ a2.3 nd installing sealing flange on gearbox side”, page 148
Sealing flange on gearbox side - specified torque and tightening

sequence

– Tighten bolts -1- to -6- in stages as follows:

Stage Tightening se‐ Specified torque
quence
1st -1- to -6- Screw onto stop by hand
2nd -1- to -6- Tighten to 10 Nm
Install intermediate plate.
– Attach intermediate plate -1- to sealing flange -2- -arrow B-.

– Slide intermediate plate onto dowel sleeves -arrows A-.
2.2 Removing and installing flywheel

♦ Counter-hold tool -3067-
Removing
• Gearbox removed
– Insert counterhold tool -3067- into hole in cylinder block
-item B-.
2. Cylinder block, gearbox end 147

– Loosen and remove flywheel bolts.

Installing
Note

♦ Flywheel with sender wheel can only be fitted in one posi‐
tion.
– Insert counterhold -3067- in hole in cylinder block -item A-.

Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 146
2.3 Removing and installing sealing flange

on gearbox side
♦ Ring spanner insert -V.A.G 1332/11-

♦ Depth gauge -VAS 6082-
♦ Assembly tool -T10134-
♦ Locating bolt -T10340-
♦ Bolt M 6 x 35, qty. 3

♦ Spark plug socket, e.g. -3122 B-
♦ Screwdriver with a shaft length of at least 250 mm
♦ Hexagon key
Note
For reasons of clarity, illustration shows work procedure with

engine removed.

insulation.
– Removing gearbox ⇒ Rep. gr. 34; Removing and installing
gearbox.

– Remove clutch ⇒ Rep. gr. 30; Removing and installing

clutch.
– Remove flywheel ⇒ a2.2 nd installing flywheel”, page 147 .
– Remove intermediate plate -1- from dowel sleeves

-arrows A-.
– Guide intermediate plate -1- upwards.
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Set crankshaft to “TDC” position ⇒ p4.7 iston to TDC posi‐
tion”, page 174 .
– Remove sump (bottom section) ⇒ a1.3 nd installing lower
part of sump”, page 302 .
– Remove upper part of sump ⇒ a1.4 nd installing upper part
of sump”, page 308 .
– Remove engine speed sender -G28- ⇒ a1.5 nd installing
engine speed senderG28”, page 585 .
– Unscrew bolts -arrows- for sealing flange -1-.
– To press off, screw qty. 3 M6 x 35 bolts -arrows- into sealing

flange -1-.

Note
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel
Note
♦ Do not re-use old sealing flange.

♦ The sealing flange with a PTFE seal is equipped with a
sealing lip support ring -2-.
♦ This support ring serves as a fitting sleeve and must not be
removed prior to installation.
♦ Sealing flange and sender wheel -1- must not be separated

after removal from packaging.
♦ The sender wheel -1- is held in its installation position on the
locating pin of the assembly tool -T10134- ⇒ page 152 .
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly tool -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft ⇒ page 152 .

Set-up of assembly tool -T10134-:
A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F-
Guide pin for petrol engines (red knob)
G - Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
I - Core
Fitting sealing flange with sender wheel on assembly tool -
T10134-:
– Screw on nut -B- until just before it touches the clamping

surface -A- of the threaded spindle.
– Clamp assembly device -T10134- at clamping surface -A- of
threaded spindle in a vice -1-.

– Press assembly housing -C- downwards until it rests against

nut -B-.
• Inner part of assembly tool and assembly housing must be
at same height.
– If fitted, remove securing clip -arrow- from new sealing
flange.
Note
Do not take the sender wheel out of the sealing flange or rotate
it out of position.
– Place sealing flange -1- with front side facing downwards on

a clean level surface.
– Push sealing lip support ring -2- downwards in

-direction of arrow- until it rests against the flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.

– Place sealing flange -1- with front side facing downwards on‐
to assembly tool -T10134- so that locating pin -D- is seated
in hole -3- in sender wheel hole -2-.
Note
♦ The sealing flange -1- can be supplied in different versions.

♦ In some circumstances, the »TDC position hole« -3- may not
be in the correct TDC position.
♦ If the position -3- is not correct in relation to the locating
pin -D-, carefully move the sender wheel -2- to the correct
position.
– If necessary, rotate sender wheel with support ring so that

locating pin and hole align.
• The sealing flange must rest flat against the assembly tool.
– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2-
against surface of assembly tool -T10134- whilst tightening
knurled screws.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel
remains fixed in assembly tool.
Mounting assembly tool -T10134- with sealing flange -1- on
crankshaft flange:
• The crankshaft flange must be free of grease and oil.

• Engine is at “TDC” position.
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool -T10134- in
-direction of arrow-, until nut -B- rests against assembly
housing -C-.
– Align flat side of assembly housing to sealing surface of
cylinder block on sump side.
– Attach assembly tool -T10134- together with sealing flange
-1- to crankshaft flange -2-.
– To do this, screw hexagon socket head bolts -E- into crank‐

shaft flange (approx. 5 full turns) using a hexagon key.
– Push guide pin for petrol engines (red knob) -F- into crank‐
shaft flange.
– To guide sealing flange -1-, screw two M6 × 35 mm bolts -2-
into cylinder block.

Bolting assembly tool -T10134- onto crankshaft flange:
– Push assembly housing -C- by hand in -direction of arrow-

until sealing lip support ring -1- rests against crankshaft
flange -2-.
– Make sure that guide pin for petrol engines (red knob) -F- is
properly seated in hole in crankshaft. This ensures that the
sender wheel reaches its final installation position.
Note
The guide pin for diesel engines (black knob) must not be inser‐
ted in threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool

hand-tight.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.
Pressing sender wheel onto crankshaft flange using assembly
tool -T10134-:

– Tighten nut -B- of assembly tool -T10134- to 35 Nm.

• After nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block -2- and sealing flange
-1-.
Checking sender wheel installation position on crankshaft:
– Screw on nut -B- until it reaches end of threaded spindle.

– Unscrew the two bolts -2- from cylinder block.
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool -T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.
– Position depth gauge -VAS 6082- on crankshaft flange -2-.
– Measure distance between crankshaft flange -2- and sender

wheel -1-.
– Measure distance -a- between crankshaft flange -2- and
sender wheel -1-.

• Specification: dimension -a- = 0.5 mm

– If specification is not achieved, press sender wheel further in
⇒ page 158 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 159 .
Re-pressing sender wheel:
– Secure assembly tool -T10134- on crankshaft flange -2-.

– Make sure that locating pin of assembly tool -T10134- is
properly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool -T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool -T10134-.
– Push guide pin for petrol engines (red knob) -F- into crank‐
shaft flange.
– Screw knurled screws -H- into sealing flange -1-.
– Screw two M6 × 35 mm bolts -2- into cylinder block to guide
sealing flange.
– Tighten nut -B- of assembly tool -T10134- to 40 Nm.

– Check sender wheel installation position on the crankshaft

again ⇒ page 157 .
– If the specification is not achieved, tighten nut of assembly
tool -T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 157 .
Installing
– Tighten bolts for sealing flange ⇒ page 146 .
– Install upper part of sump ⇒ a1.4 nd installing upper part of
sump”, page 308 .
– Install bottom section of sump ⇒ a1.3 nd installing lower part
– Install intermediate plate ⇒ page 147 .
– Install flywheel ⇒ a2.2 nd installing flywheel”, page 147 .
Specified torques
♦ Sealing flange on gearbox side - specified torque and tight‐
ening sequence ⇒ Fig. ““Sealing flange on gearbox side -
specified torque and tightening sequence”“, page 146
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 146
♦ ⇒ o1.1 verview - ignition system”, page 578
♦ ⇒ o1.1 verview - sump/oil pump”, page 298
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – speci‐
fied torque”“, page 128
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ Rep. gr. 34; Removing and installing gearbox; Specified
torques for gearbox

3 Crankshaft
⇒ n3.1 eedle bearing in crankshaft”, page 160
⇒ d3.2 imensions”, page 163
⇒ a3.3 xial clearance of crankshaft”, page 163
3.1 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
Note
♦ For vehicles with manual gearbox, no needle bearing must

be installed in the crankshaft.
♦ On vehicles with dual clutch gearbox, a needle bearing must
be installed in the crankshaft ⇒ Electronic Parts Catalogue.

♦ Counter support, e.g. KUKKO 22-1 -VAS 251 621-
♦ Internal puller -VAS 251 635-
♦ Pin -VW 207 C-

♦ Centring mandrel -3176-
Condition:
• Gearbox is removed ⇒ Rep. gr. 34; Removing and installing

gearbox; Removing gearbox.
• Always renew needle bearing -arrow- after separating en‐
gine and gearbox.
• The front edges of the inner puller must be free of chips.
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-.
3. Crankshaft 161
Installing
– Clean bearing seat in crankshaft and apply as thin coating of

grease.
Note
The lettering on the needle bearing must be visible when instal‐

led.
– Using drift -VW 207 C-, drive needle bearing into crankshaft
as far as installation depth -a-.
Installation depth: dimension -a- = 0.0 mm
Note
If the needle bearing has been driven in too far, it must be

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

– Install gearbox ⇒ Rep. gr. 34; Removing and installing gear‐

box; Installing gearbox.
3.2 Crankshaft dimensions

NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
damage to the bearings will result.
– Never remove the crankshaft.
Measuring the main bearing clearance is not possible with nor‐

mal workshop equipment.
Honing dimension Conrod bearing journal diameter
mm
Basic dimension 48.00 -0.022
-0.042
3.3 Measuring axial clearance of crank‐

shaft
NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
damage to the bearings will result.
– Never remove the crankshaft.

♦ Universal dial gauge holder -VW 387-
3. Crankshaft 163
♦ Dial gauge -VAS 6079-
– Screw dial gauge -VAS 6079- with universal dial gauge

bracket -VW 387- to cylinder block as shown in the illustra‐
tion.
– Position dial gauge against crank web.
– Press crankshaft against dial gauge by hand and set gauge
to “0”.
– Push crankshaft away from dial gauge and read off meas‐
ured value.
• Axial clearance: 0.066 to 0.233 mm

4 Pistons and conrods

⇒ o4.1 verview - pistons and conrods”, page 165
⇒ a4.2 nd installing pistons”, page 168
⇒ a4.3 nd installing oil spray jets”, page 169
⇒ p4.4 istons and cylinder bores”, page 170
⇒ r4.5 adial clearance of conrods”, page 173
⇒ n4.6 ew conrod”, page 173
⇒ p4.7 iston to TDC position”, page 174
4.1 Assembly overview - pistons and conrods
4. Pistons and conrods 165

1 - Bolts
❑ Oil threads and contact
surface
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one posi‐
tion and only on the
appropriate conrod due
to the breaking proce‐
dure (cracking) sepa‐
rating the cap from the
conrod.
❑ Mark allocation to cylin‐
der and conrod in col‐
our -B-.
❑ Installation position:
Lug -A- on conrod
bearing cap faces to‐
wards pulley end
3 - Bearing bushes
❑ Fitting position ⇒ page
167
❑ Renew worn bearing
shells
❑ Ensure firm seating
4 - Pressure relief valve
❑ 27 Nm
5 - Oil spray jet
❑ For piston cooling
ling oil spray jets”, page
169
6 - Locking ring
❑ Qty. 2
7 - Piston pin
❑ Removing and installing ⇒ a4.2 nd installing pistons”, page 168
8 - Piston
❑ Mark installation position and cylinder number ⇒ page 167 .
❑ Removing and installing ⇒ a4.2 nd installing pistons”, page 168
❑ Checking piston and cylinder bore ⇒ p4.4 istons and cylinder bores”, page 170
9 - Piston rings
❑ Compression rings
❑ Measuring ring gap ⇒ page 171
❑ Measuring ring-to-groove clearance ⇒ page 171
❑ Use commercially available piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gaps by 120°
10 - Piston ring

❑ Oil scraper ring
❑ Measuring ring gap ⇒ page 171
❑ Measuring ring-to-groove clearance ⇒ page 171
❑ Use piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gap 120° relative to lower compression ring
11 - Connecting rod
❑ With industrially cracked conrod bearing cap
❑ Renew as set only.
❑ Mark allocation to cylinder and conrod bearing cap in colour -B-.
❑ Measuring radial clearance ⇒ r4.5 adial clearance of conrods”, page 173
❑ Separate new conrod ⇒ n4.6 ew conrod”, page 173 .
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end
Installation position and allocation of piston to cylinder
– If worn pistons are to be reinstalled, mark their allocation to

the cylinder on the piston crown.
– Use paint for this.
– Do not use indentation, scratches, notches, or similar to
mark piston crown.
• Arrow on piston crown points to pulley end -arrow-.
Bearing shells - installation position

• Ensure that crankshaft bearing shell is correctly positioned in

conrod and conrod bearing cap.
• Dimension -a- must be the same as dimension -a-.
4.2 Removing and installing pistons

♦ Pin -VW 222 A-
♦ Piston ring clamp, commercially available

Removing
– Remove cylinder head ⇒ a1.3 nd installing cylinder head”,
page 185 .
– Mark piston installation position and corresponding cylinder
number.
– Mark installation position and matching of cylinder and con‐
rod bearing cap to conrod ⇒ Item 11 (page 167) .
– Remove conrod bearing cap and withdraw piston and con‐
rod upwards.
Note
If the piston pin is difficult to move, heat the piston to approx.

60°C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift -VW 222 A-.
Installing
Note
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ page 167 .
– Install conrod bearing cap, noting installation position ⇒ Item
2 (page 166) .

– Install cylinder head ⇒ a1.3 nd installing cylinder head”,

page 185 .
sump”, page 308 .
Specified torques
♦ ⇒ o4.1 verview - pistons and conrods”, page 165
4.3 Removing and installing oil spray jets

♦ Hexagon key -T10545-
Removing
insulation.
Note
♦ The crank web of the respective cylinder must be positioned

so that the socket -T10545- can be inserted vertically in the
pressure relief valve.
♦ Furthermore, the corners of the socket -T10545- and of the
pressure relief valve must engage well.
– Turn crankshaft via vibration damper securing bolt in direc‐

tion of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using TORX bit -T10545-.

– Remove oil spray jets -2-.

Installing
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
Install in reverse order of removal. The following should be

observed:
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Check clearance of oil jets after reinstallation of pistons.
– Bent oil spray jets must be renewed.

1- Pressure relief valve - 27 Nm ⇒ Item 4 (page 166)
2- Oil spray jet
sump”, page 308 .
insulation.
4.4 Checking pistons and cylinder bores

♦ External micrometer 50-75 mm -VAS 6070-
Checking piston

– Using an external micrometre, measure approx. 10 mm from

lower edge, offset 90° from piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston diameter, mm
Specification 74.421)
• 1) Dimensions without coating
• Piston manufacturer Federal Mogul (thickness of 0.018 mm
per side)
• Piston manufacturer Mahle (thickness of 0.015 mm per
side)
Measuring piston ring gap
– Push in piston ring at right angles to cylinder wall.

– Push piston ring from below into cylinder bore as far as
approx. 15 mm from bottom end of cylinder.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
compression ring 0.20 +0.15 0.7
Oil scraper ring (2 parts) 0.20 +0.20 1.0
Oil scraper ring (3 parts) 0.50 +/-0.25 1.2
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.

Piston ring New Wear limit
mm mm
1st compression ring 0.050 … 0.090 0.15
(piston ring manufacturer
Federal Mogul)
1st compression ring 0.035 … 0.085 0.15
(piston ring manufacturer
Mahle)
2nd compression ring 0.030 … 0.070 0.15
Oil scraper rings (3 parts) Cannot be measured
Oil scraper rings (2 parts) 0.04 … 0.08
Measuring cylinder bore
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Using cylinder gauge -VAS 6078-, take measurements at

3 positions: diagonally, in lateral direction -a- and longitudi‐
nal direction -b-.
• Maximum deviation from nominal dimension: 0.08 mm.

Cylinder bore diameter, mm

Specification 74.5 + 0.015
+0.005
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support -VAS 6095-, as measurements
may be incorrect.
4.5 Checking radial clearance of conrods

♦ Plastigage
– 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).
– Do not rotate crankshaft while doing so.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.028 to 0.065 mm.
– Renew conrod bolts.
4.6 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap
cannot be removed by hand:
– Mark the cylinder to which the conrod belongs ⇒ Item 11
(page 167) .
– To avoid damage, gently clamp conrod in a vice with protec‐

tion jaws, as shown in illustration.
– Clamp conrod below dashed line.
– Unscrew bolts -arrows- around 5 turns.

– Using a plastic hammer, carefully knock against conrod

bearing cap -arrow- until it is loose.
4.7 Setting piston to TDC position

Setting piston from cylinder no. 1 to TDC position ⇒ page 174
Setting piston from cylinder no. 1 to TDC position for repair
work on toothed belt drive and for setting valve timing ⇒ page
176
Setting piston from cylinder no. 1 to TDC position
Rotate crankshaft to “TDC” as follows:
– Remove ignition coil 1 with output stage -N70- and the spark
plug cylinder 1 ⇒ a1.2 nd installing ignition coils with output
stage”, page 580 .
Note
♦ Risk of damage to engine!

♦ Locking pin -T10340- can be inserted to stop at 2 positions.
♦ It is essential that the “TDC” position is checked as descri‐
bed.
– Carefully insert a screwdriver with a shaft length of at least

250 mm into spark plug hole so that it contacts piston crown.
– Turn crankshaft in direction of engine rotation until piston in
cylinder 1 is at “BDC”.
The screwdriver moves in the -direction of the arrow-.

– Turn crankshaft further in direction of engine rotation until

screwdriver has moved -30 mm- in -direction of arrow-.

insulation.
– Unscrew plug for “TDC” hole in cylinder block.

– Screw locking pin -T10340- into cylinder block as far as stop

and tighten to 30 Nm.
– Rotate crankshaft in normal direction of rotation as far as
stop.
• The locking pin now rests against the crank web.
Note
Locking pin -T10340- locks crankshaft in direction of engine

rotation only.
Setting piston from cylinder no. 1 to TDC position for repair

work on toothed belt drive and for setting valve timing
– Remove air intake pipe ⇒ a2.5 nd installing air pipe”, page
441 .
– Press release tabs and disconnect hose -1- for activated
charcoal filter.
– Unscrew bolts -arrows- and pull off crankcase breather

hose.
Note
Risk of chemical damage to the coolant pump gasket caused by

oil entering between the coolant pump and the cylinder head.
– Cover coolant pump with a cloth.

– Remove connection for turbocharger ⇒ a1.4 nd installing
connection for turbocharger”, page 429 .
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1, 3- and remove cover -2- for toothed belt
for coolant pump.
– Unscrew bolts -arrows- and detach sealing cap -1-.
• The asymmetrically positioned grooves on gearbox end of

both camshafts -top arrows- must now be above the horizon‐
tal centre line.
• Grooves -arrows- on exhaust camshaft -A- can be accessed

through recesses in drive wheel for coolant pump.
• On inlet camshaft -E-, grooves -arrows- are above horizontal
camshaft centre line.
A - Exhaust camshaft
E - Inlet camshaft

Plug for “TDC” drilling in cylinder block - specified torque
♦ Renew O-ring if damaged.

♦ Tighten bolt -arrow- to 30 Nm.
Specified torques
♦ ⇒ o1.1 verview - turbocharger”, page 416
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 348
♦ ⇒ o1.2 verview - camshaft housing”, page 181

15 – Cylinder head, valve gear

1 Cylinder head
⇒ o1.1 verview - cylinder head”, page 179
⇒ o1.2 verview - camshaft housing”, page 181
⇒ a1.3 nd installing cylinder head”, page 185
⇒ a1.4 nd installing camshaft housing”, page 190
⇒ c1.5 ompression”, page 196
1.1 Assembly overview - cylinder head
Note
♦ The camshafts must not be removed individually.

♦ In the event of repair, the camshaft housing must be re‐
newed completely.
1. Cylinder head 179

1 - Cylinder head gasket

❑ Renew after removal ⇒
a1.3 nd installing cylin‐
der head”, page 185
❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Dowel sleeve
❑ Qty. 2
3 - Cylinder head
cylinder head”, page
185
❑ Check for distortion ⇒
page 181 .
4 - Dowel pins
5 - Seal
❑ With oil strainer
❑ Inserted into cylinder
head
Note
♦ The oil strainer is fitted only if

the cylinder head has the ap‐
propriate recess.
♦ Cylinder heads without recess
do not require an oil strainer.
6 - Seal
7 - Camshaft case
❑ Removing and installing ⇒ a1.4 nd installing camshaft housing”, page 190
8 - Bolt
9 - Bolt
❑ Sequence when loosening ⇒ page 188 .
Cylinder head - specified torque and sequence
180 Rep. gr.15 - Cylinder head, valve gear

Note

1st -1 … 10- 40 Nm
2nd -1 … 10- Turn 90° further
4th -1 … 10- Turn 90° further
Checking cylinder head for distortion
– Use straight edge 500 mm -VAS 6075- and feeler gauge to

measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.05 mm
1.2 Assembly overview - camshaft housing

⇒ o1.2.1 verview - camshaft housing, exhaust side with toothed
belt pulley”, page 181
⇒ o1.2.2 verview - camshaft housing, exhaust side with cam‐
shaft adjuster”, page 183
1.2.1 Assembly overview - camshaft housing, exhaust side with toothed belt
pulley

1 - Bolt
page 183
2 - Inlet camshaft control
valve 1 -N205-
camshaft control valve
1N205”, page 282
3 - Bolt
❑ 8 Nm
4 - Camshaft case
ling camshaft housing”,
page 190
5 - Hall sender -G40-
ling ⇒ a1.4.1 nd instal‐
ling Hall senderG40”,
page 584
6 - Bolt
❑ 8 Nm
7 - Seal
❑ For exhaust camshaft,
gearbox end
❑ Renewing ⇒ a3.2.5 nd
installing camshaft oil
seal, exhaust camshaft,
gearbox end ”, page
254
8 - Crankshaft
❑ For coolant pump
❑ Removing and installing ⇒ a2.7 nd installing toothed belt pulley for coolant pump”, page 366
9 - Bolt
❑ Specified torque ⇒ Item 8 (page 349)
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
❑ Renew
13 - Seal
❑ Renew
14 - Dowel pin
15 - Seal
❑ Inserted into cylinder head
Note


propriate recess.
16 - Seal
❑ For inlet camshaft
❑ Renewing ⇒ a3.2.2 nd installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side
with camshaft adjuster”, page 246
17 - Seal
❑ For exhaust camshaft (pulley end)
❑ Renewing ⇒ a3.2.4 nd installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust
side with camshaft adjuster”, page 251
18 - Cap
Camshaft housing - specified torque and tightening sequence
Note

1st -1 … 15- 10 Nm
1.2.2 Assembly overview - camshaft housing, exhaust side with camshaft ad‐
juster

1 - Exhaust camshaft control

valve 1 -N318-
exhaust camshaft con‐
trol valve 1N318”, page
283
2 - Bolt
❑ 8 Nm
valve 1 -N205-
1N205”, page 282
4 - Camshaft case
page 190
5 - Hall sender 3 -G300-
ling ⇒ a1.4.2 nd in‐
stalling Hall sender
3G300”, page 584
6 - Bolt
❑ 8 Nm
ling Hall senderG40”,
page 584
8 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing ⇒ a3.2.5 nd installing camshaft oil seal, exhaust camshaft, gearbox end ”, page 254
9 - Crankshaft
10 - Bolt
❑ Specified torque ⇒ Item 8 (page 349)
11 - Bolt
❑ 8 Nm
12 - Cap
13 - O-ring
❑ Renew
14 - Seal
❑ Renew
15 - Dowel pin
16 - Seal
❑ Inserted into cylinder head

Note

propriate recess.
17 - Seal
❑ For inlet camshaft
❑ Renewing ⇒ a3.2.2 nd installing camshaft oil seal, for inlet camshaft on belt pulley side, exhaust side
18 - Seal
❑ For exhaust camshaft (pulley end)
❑ Renewing ⇒ a3.2.4 nd installing camshaft oil seal, for exhaust camshaft on belt pulley side, exhaust
19 - Cap
20 - Bolt
Camshaft housing - specified torque and tightening sequence
Note

1st -1 … 15- 10 Nm
1.3 Removing and installing cylinder head


♦ Commercially available razor blade scraper (blade width:

40 mm)
Removing
Note
♦ Seal open channels of intake and exhaust system with suita‐

ble plugs from engine bung set -VAS 6122-.
♦ Cover the openings in the gearbox with a cloth to prevent
any coolant or other liquids from getting into the clutch hous‐
ing.
♦ Fit the cable ties in the original position when installing.
♦ Fit all heat shield sleeves in the same place when installing.
– Remove camshaft housing ⇒ a1.4 nd installing camshaft

housing”, page 190 .
– Remove intake manifold ⇒ a4.2 nd installing intake mani‐
fold”, page 481 .
– Disconnect connectors:
1- On oil pressure switch for reduced oil pressure -F378-

2- On fuel pressure sender -G247-
3- At injectors


– Unscrew bolts -arrows- and remove heat shield for right
drive shaft.
– Separate electrical connector -4- on oil pressure switch -F1-

-3-.
– Remove bolts -arrows- and detach oil supply line -1- and oil
return line -2-.
– Disconnect connectors -1- and -2-:

1 - For coolant temperature sender -G62-

2 - For charge pressure positioner -V465-
– Unscrew bolt -1- from engine support.
– Loosen cylinder head bolts in the sequence -1 to 10- and

unscrew.
– Take off cylinder head and set it down on a soft surface

(foam plastic).

Installing
Note
♦ Using unauthorised sanding or abrasive media may lead to

secondary damage such as, for example, damage to the
turbocharger or the conrod bearings.
♦ Do not use sandpaper, grinding wheels, abrasive or scour
pads or any other sanding or abrasive media.
♦ When removing the sealant residue, make sure no loose
particles get into the open channels of the engine.
Note
♦ Do not use any other means rather than a standard blade

scraper to remove the sealant residue from the cylinder
head and cylinder block. Take care not to damage the seal‐
ing surfaces.
♦ Remove any loose remains using a lint-free cloth.
♦ Remove oil or coolant from blind holes of cylinder head
bolts.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Make sure to prevent damage to the silicone coating or the
indented area of the gasket.
Note

♦ Renew self-locking nuts as well as gaskets, seals and O-
rings.
♦ When installing a replacement cylinder head, the contact
surfaces between hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
camshaft housing.
to production standard ⇒ Electronic parts catalogue.
♦ Do not reuse coolant which has been drained off.
– Fit cylinder head gasket -1-.

♦ Note centring pins in cylinder block -arrows-.

♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
– If the crankshaft has been turned in the meantime, set piston
of no. 1 cylinder to TDC.
– Turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten bolts for cylinder head ⇒ page 180 .
Note
After repair work it is not necessary to retighten the cylinder

head bolts.

– Install camshaft housing ⇒ a1.4 nd installing camshaft hous‐
ing”, page 190 .
– Install intake manifold ⇒ a4.2 nd installing intake manifold”,
page 481 .
– Change engine oil ⇒ Maintenance; Booklet .
– Add coolant ⇒ a1.3 nd adding coolant”, page 340 .
Specified torques
♦ ⇒ Fig. ““Engine support - specified torque and installation
sequence”“, page 70
♦ ⇒ o1.1 verview - cylinder head”, page 179
♦ ⇒ o4.1 verview - intake manifold”, page 478
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Assembly overview - drive shaft
1.4 Removing and installing camshaft

housing
Removing
– Remove coolant pump ⇒ a2.5 nd installing coolant pump”,
page 356 .
ing”, page 472 .
– Remove ignition coils ⇒ a1.2 nd installing ignition coils with
output stage”, page 580 .
– Remove toothed belt from camshafts ⇒ t2.8 oothed belt from
camshaft”, page 234 .

– Detach hose clip -2- and pull off hose.

– Remove high-pressure pipe -3- ⇒ a7.3 nd installing high-
pressure pipe”, page 527 .
– Release hose clip -2- and detach coolant hose.
– Remove bolts -arrows- and pivot coolant lines -1- to right

side.
– Unscrew bolts -arrows-, and remove heat shield -1-.
– Disconnect connector -arrow- from intake manifold sender

-GX9-.

Vehicles without variable valve timing on exhaust side
2 - For camshaft adjuster valve 1 -N205-
4 - for Hall sender -G40-
– Remove bolt -3-, move wiring harness clear and place to left
side.
– Pull out dipstick -1-.
Vehicles with variable valve timing on exhaust side
Note
The number of electrical connectors varies depending on the

engine code.
1 - Only for vehicles with Active Cylinder Management (ACT)

2 - For Hall sender -G40- and Hall sender 3 -G300-

4 - For camshaft control valve 1 -N205- and exhaust camshaft
control valve 1 -N318-
– Unscrew bolt -3- and lay wiring harness to one side.
– Pull out dipstick -5-.
– Loosen bolts for camshaft housing in the sequence -15 to 1-
and unscrew.
– Carefully detach camshaft housing from adhesive bond and

remove it.
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐

sation element -4- and valves -3- for reinstallation.
– Remove roller rocker fingers together with compensation el‐
ements and place them on a clean surface.
Installing
observed:
Note

♦ Renew gasket and seal with oil strainer.

NOTICE
Risk of damage to valve gear caused by axial movement of
the camshafts.
– Never move camshafts in axial direction when turning
them.
• Locking pin -T10340- screwed into cylinder block as far as

stop and tightened to 30 Nm.
• Crankshaft has been turned in direction of engine rotation

until it rests against locking pin -T10340- = “TDC” position ⇒
page 174 .
– Make sure that all roller rocker fingers -1- rest properly
against end of valve stem -3-.
– Make sure that all roller rocker fingers -1- are clipped into
the respective hydraulic compensation element -4-.
– Make sure that camshafts are set to »TDC« position for pis‐
ton of cylinder no. 1 ⇒ page 176 .
– Fit seal with oil strainer -2- into cylinder head -1-.

Note
♦ The oil strainer is fitted only if the cylinder head has the
appropriate recess.
♦ Cylinder heads without recess do not require an oil strainer.
– Fit gasket onto dowel pins -arrows-.

– Screw 2 studs -items 2, 4- (e.g. -T10288/4-) into cylinder
head.
– Carefully lower camshaft housing -3- vertically onto studs in

cylinder head.
Note
Ensure that camshaft housing is not canted.
– Tighten bolts for camshaft housing.

Continue installation in reverse order of removal. The following
should be observed:
– Install high-pressure pipe ⇒ a7.3 nd installing high-pressure
pipe”, page 527 .
– Install toothed belt (adjust valve timing) ⇒ t2.8 oothed belt
from camshaft”, page 234 .
– Install ignition coils ⇒ a1.2 nd installing ignition coils with
output stage”, page 580 .
– Install coolant pump ⇒ a2.5 nd installing coolant pump”,
page 356 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Risk of damage to engine
Avoid damage to valves and piston crowns after working on
valve gear.

♦ Turn the engine carefully at least 2 rotations to ensure that

none of the valves make contact when the starter is operat‐
ed.
Specified torques
♦ ⇒ Fig. ““Camshaft housing - specified torque and tightening
♦ ⇒ o1.2.2 verview - camshaft housing, exhaust side with cam‐
1.5 Checking compression

♦ Spark plug socket -3122 B-
♦ Compression tester -V.A.G 1763-
• Engine oil temperature at least 30°C.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from fuse holder.
Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Start engine and run it until it turns off.

– Switch off ignition.

– Remove resonator for intake air. ⇒ a3.4 nd installing resona‐

– Pull off connector -2- and unscrew bolt -1-.
– Pull out ignition coils with output stages.

– Unscrew spark plugs using spark plug socket and extension
-3122 B-.
– Check compression pressure using compression tester -
V.A.G 1763-; refer to ⇒ Operating instructions.
– Have a second mechanic press down accelerator completely
and simultaneously operate starter until pressure no longer
increases on tester display.
– Repeat procedure on each cylinder.
Compression pressures bar
New 10.0 … 15.0
Wear limit 7.0
Maximum difference between cylinders 3.0
Installing
Assembly is carried out in reverse sequence; note the following:
– Install spark plugs.
– Install ignition coils with output stages ⇒ a1.2 nd installing
ignition coils with output stage”, page 580 .
– Entries are stored in the event memory of the engine con‐
trol unit because electrical connectors were disconnected
and the engine was started: Generate readiness code in
Guided functions ⇒ Vehicle diagnostic tester.
Specified torques

2 Toothed belt drive

⇒ o2.1 verview - toothed belt cover”, page 198
⇒ o2.2 verview - toothed belt”, page 199
⇒ a2.3 nd installing toothed belt guard”, page 203
⇒ a2.4 nd installing valve timing tool”, page 205
⇒ v2.5 alve timing”, page 213
⇒ v2.6 alve timing”, page 216
⇒ a2.7 nd installing toothed belt”, page 227
⇒ t2.8 oothed belt from camshaft”, page 234
2.1 Assembly overview - toothed belt cover
1 - Lower toothed belt guard

ling lower toothed belt
guard”, page 204
2 - Bolt
❑ 8 Nm
3 - Engine support
tightening sequence
(Golf Cabriolet, Sciroc‐
co, CC) ⇒ page 70
tightening sequence
(Sharan, Tiguan) ⇒
page 73
tightening sequence (T-
Roc) ⇒ page 76
4 - Bolt
tightening sequence
(Golf Cabriolet, Sciroc‐
co, CC) ⇒ page 70
tightening sequence
(Sharan, Tiguan) ⇒
page 73
tightening sequence (T-
Roc) ⇒ page 76
5 - Upper toothed belt guard
ling upper toothed belt
guard”, page 203
6 - Bolt
❑ 8 Nm

2.2 Assembly overview - toothed belt

⇒ o2.2.1 verview - toothed belt, exhaust side with toothed belt
pulley”, page 199
⇒ o2.2.2 verview - toothed belt, exhaust side with camshaft
adjuster”, page 201
2.2.1 Assembly overview - toothed belt, exhaust side with toothed belt pulley
2. Toothed belt drive 199

1 - Toothed belt
direction of rotation
with chalk or felt-tipped
marker pen.
❑ Check for wear
toothed belt”, page 227
❑ Do not bend excessive‐
ly ⇒ page 230
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and instal‐
lation involve remov‐
ing engine support ⇒
a1.6 nd installing en‐
gine support”, page
136 .
4 - Bolt
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
ling toothed belt pulley”,
page 277
6 - Inlet camshaft toothed belt
pulley
❑ With camshaft adjuster
ling camshaft adjuster ⇒ a3.3 nd installing camshaft adjuster”, page 256
7 - Guide bush
8 - Bolt
❑ 50 Nm +135°
9 - O-ring
❑ Renew if damaged
10 - Plug
❑ 20 Nm
11 - O-ring
❑ Captive, supplied with “item 13”.
12 - Spacer sleeve
❑ Supplied with item “13”.
13 - Idler roller
14 - Bolt
❑ 40 Nm
15 - Crankshaft pulley

❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Plug for “TDC” drilling in cylinder block - specified torque
Note
Renew O-ring if damaged.

Bolt -arrow- 30 Nm
2.2.2 Assembly overview - toothed belt, exhaust side with camshaft adjuster

1 - Toothed belt
direction of rotation
with chalk or felt-tipped
marker pen.
❑ Check for wear
toothed belt”, page 227
❑ Do not bend excessive‐
ly ⇒ page 230
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and instal‐
lation involve remov‐
ing engine support ⇒
a1.6 nd installing en‐
gine support”, page
136 .
4 - Bolt
❑ 8 Nm
❑ Tightening and loosen
the bolts diagonally and
evenly
5 - Cap
6 - Bolt
❑ 50 Nm +135°
7 - Exhaust camshaft toothed
belt pulley
❑ Removing and installing camshaft adjuster ⇒ a3.3 nd installing camshaft adjuster”, page 256
8 - Guide bush
9 - Inlet camshaft toothed belt pulley
❑ Removing and installing camshaft adjuster ⇒ a3.3 nd installing camshaft adjuster”, page 256
10 - Bolt
❑ 50 Nm +135°
11 - O-ring
12 - Plug
❑ 20 Nm
13 - Spacer sleeve
❑ With O-ring
❑ Renew O-ring
❑ Supplied with item “14”.
14 - Idler roller

15 - Bolt
❑ 40 Nm
16 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
2.3 Removing and installing toothed belt

guard
⇒ a2.3.1 nd installing upper toothed belt guard”, page 203
⇒ a2.3.2 nd installing lower toothed belt guard”, page 204
2.3.1 Removing and installing upper toothed

belt guard
Removing
– Separate plug-in connectors from fuel hose and from hose
to activated charcoal filter ⇒ Rep. gr. 20; plug-in connectors;
Separating plug-in connectors.
bracket -d-.
– Detach hoses from retainer -3-.

– Release clips -arrows- and remove upper toothed belt guard

-1-.
Installing
Further assembly is carried out in the reverse order of removal.
Specified torques
2.3.2 Removing and installing lower toothed

belt guard
Removing
– Remove vibration damper ⇒ a1.5 nd installing vibration

damper”, page 134 .
– Unscrew bolts -arrows- and remove toothed belt guard.
NOTICE
Installing
Specified torques

2.4 Preassembling and installing valve tim‐

ing tool
⇒ t2.4.1 est toolVAS 611 007”, page 205
⇒ t2.4.2 est toolVAS 611 007”, page 208
⇒ t2.4.3 est toolVAS 611 007 electronically and performing ba‐
sic setting”, page 211
2.4.1 Preassembling test tool -VAS 611 007-

♦ Tester for checking elongation of chain links -VAS 611 007-
Test tool -VAS 611 007-

A - Angle sensor -VAS 611

007/1-
❑ Specified torque brake:
11 Nm
B - Lock ring -VAS 611 007/2-
C - Clamping ring -VAS 611
007/3-
D - Adapter for camshaft
housing -VAS 611 007/8-
E - Adapter for angle sensor
-VAS 611 007/9- and adapt‐
er for angle sensor -VAS 611
007/10-
❑ Adapter for angle sen‐
sor -VAS 611 007/9-
blue, for inlet camshaft
❑ Adapter for angle sen‐
sor -VAS 611 007/10-
red, for exhaust cam‐
shaft
Preassembling test tool -VAS 611 007-
– Before installing the adapters for angle sensor -E- in angle

sensors -A-, check correct assignment by means of the col‐
our coding -a-.
– Insert corresponding adapter for angle sensor -E- in relevant
angle sensors -A-.
– Note position of dowel pins -a- when installing.
– Adapters for angle sensors -E- can only be fitted in one
position.

– Make sure that brake -b- is released. Do not apply force.

– Insert adapter for angle sensors -E- in angle sensors -A- as
far as stop.
– Secure clamp rings -C- in groove -a- of respective adapter

for angle sensors -E-.
– Insert angle sensor -A- colour coded red on red marked
side -arrows a- of camshaft housing adapter -D-. To do this,
release locking pin -c- by pulling it upwards.
– Insert angle sensor -A- colour coded red and push in until
locking pin -c- can be heard to engage.
– Repeat procedure with angle sensor -A- colour coded blue.
– To do this, observe colour coding -arrows b-.

– Screw in red and blue lock ring -B- approx. 2 turns. Note
colour coding -arrows a- and -arrows b- when doing this.
Note
♦ Screw in securing rings -VAS 611 007/2- -B- max. 2 turns by

hand.
♦ If the lock rings are turned too tightly -B-, the angle sensors
-VAS 611 007/1- could become damaged.
– Check for freedom of movement of the adapters for angle

sensors.
• It should be possible to turn adapters for angle sensors with
ease.
2.4.2 Installing test tool -VAS 611 007-


– Preassemble test tool -VAS 611 007- ⇒ t2.4.1 est toolVAS
611 007”, page 205 .
– Teach-in test tool -VAS 611 007- electronically and perform
basic setting ⇒ t2.4.3 est toolVAS 611 007 electronically and
performing basic setting”, page 211
– Turn adapter for angle sensor -VAS 611 007/9- and adapter
for angle sensor -VAS 611 007/10- until display is set to
approx. 0°.
– Perform the preliminary work for checking the valve timing ⇒
v2.5 alve timing”, page 213 .
– Make sure that the piston in cylinder no. 1 is at TDC position
⇒ p4.7 iston to TDC position”, page 174 .
– Make sure that brakes on angle sensor -VAS 611 007/1- are
released on both sides ⇒ page 207 .
Note
Before positioning the test tool -VAS 611 007- against the cam‐
shaft housing, the grooves of the camshafts must be checked
for damage.
– Align adapter for angle sensor -E- by hand with grooves of

camshafts -arrows-.
– Check proper alignment through recess, and adapt position

by turning.
– Fit adapter for camshaft housing -VAS 611 007/8- -D- to
camshaft housing, and slide it on.
– Tighten knurled screws -arrows a- alternately by hand.

– Make sure that adapter for camshaft housing -VAS 611

007/8- -D- is properly seated.
Note
♦ If camshaft housing adapter -VAS 611 007/8- -D- touches

the housing of the coolant pump, the basic setting of the
coolant pump is incorrect.
♦ In this case, correct adjustment or testing of the valve timing
is not possible.
♦ The coolant pump must be removed and readjusted ⇒
a2.5 nd installing coolant pump”, page 356 .
• Test tool -VAS 611 007- must rest flush against camshaft
housing.
– Make sure that brakes on angle sensor -VAS 611 007/1- are
released on both sides ⇒ page 207 .
– Tighten locking ring -VAS 611 007/2- -B- on both sides
evenly by hand. When doing this, ensure that camshaft
housing adapter -VAS 611 007/8- -D- always lies flat against
camshaft housing -1-.
• Camshaft housing adapter -VAS 611 007/8- -D- should not

lift off of camshaft housing -1-.
Note
The correct preload is achieved when the camshaft housing

adapter -VAS 611 007/8- lies flat -a- against the camshaft hous‐
ing.
– Make sure that brakes -a- are released on both sides.

2.4.3 Teaching-in test tool -VAS 611 007-

electronically and performing basic set‐
ting
– Connect electronic measuring equipment of test tool -VAS

611 007- ⇒ Operating manual.
– Perform software installation of test tool -VAS 611 007-
⇒ Operating manual.
– Start test program ⇒ Operating manual.
If angle sensors are not connected, message shown in illustra‐
tion is displayed.
– Connect test tool -VAS 611 007-, and press CONNECT .
If test tool -VAS 611 007- is connected, display is as shown:

ANW - Exhaust camshaft, red

ENW - Inlet camshaft, blue
– Turn adapter for angle sensor -VAS 611 007/10- red -E- for
exhaust camshaft.
If »OK« is displayed, teach-in of exhaust camshaft is success‐

ful.
– Turn adapter for angle sensor -VAS 611 007/9- blue -E- for
inlet camshaft.
If display is as shown in illustration, exhaust camshaft has been
taught-in.
– Select function MEASURE .

If display is as follows:

– Check valve timing ⇒ v2.5 alve timing”, page 213 .

– Make sure that brake indicator on display is green.
• It must not be yellow or red.

A - Green, brake is released
B - Yellow, brake is applied
C - Red, brake has been tightened to torque
2.5 Checking valve timing


– Set piston for cylinder no. 1 to TDC position ⇒ p4.7 iston to
TDC position”, page 174 .
– Unscrew bolts -2-.
– Remove cover for thermostat housing -1-.

– Unclip wiring harness -3- and place to one side.

– Place a cloth underneath to catch any oil which may drain
out.
– Take off cap -5-.
– Pull off pipe -2-.
– Remove toothed belt cover -4-.
– Preassemble test tool -VAS 611 007- ⇒ t2.4.1 est toolVAS
611 007”, page 205 .

– Install test tool -VAS 611 007- ⇒ t2.4.2 est toolVAS 611
007”, page 208 .
– Make sure that brakes -a- are released on both sides.
– Make sure that brake indicator on display is green -A-.
• It must not be yellow or red.

– Unscrew locking pin -T10340- -A-.
– Turn crankshaft 2 turns in direction of rotation of engine.

– Screw in locking pin -T10340- -A-.

– Read valve timing angles on display, and compare values

with specifications.
Specified values
Inlet camshaft Exhaust camshaft
-0.5° ±1.5° +1.5° ±1.5°
Note
♦ Adjust valve timing as precisely as possible. The settings

must be as close to the specifications as possible.
♦ The valve timing must not be outside the tolerance limits.
– If necessary, adjust timing ⇒ v2.6 alve timing”, page 216 .

Specified torques
♦ ⇒ Brake system; Rep. gr. 45; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
Component Specified torque
Bolt for TDC hole 30 Nm
in cylinder block
2.6 Adjusting valve timing


• Toothed belt installed.
– Do not relieve tension from toothed belt, and do not remove
toothed belt from camshafts when adjusting valve timing.
Only loosen camshaft adjuster or toothed belt sprocket.
– Loosen camshaft adjuster on inlet side ⇒ page 258 .
Exhaust side with toothed belt sprocket
– Loosen toothed belt sprocket on exhaust side ⇒ page 278 .
Exhaust side with camshaft adjuster
– Loosen camshaft adjuster on exhaust side ⇒ page 273 .
Continuation for all vehicles
NOTICE
– Place a cloth under the camshaft adjusters and over tension‐

ing roller to catch the engine oil which runs out.
• The contact points between the toothed belt and compo‐
nents - such as camshaft pulleys, tensioning roller and idler
pulley - must be kept free of oil.
• Catch any engine oil which runs out immediately, and re‐
move it.
• Remove engine oil at camshaft adjusters.


– Renew bolt -2- and screw in loosely.


• It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:
– Make sure that bolts -a- for brakes are released on both
sides.
– Make sure that the brake indicator on the display
is »green« -A-.

– Display must not be »yellow« or »red«.

– Set both camshafts to »0.0°«.
– To do this, turn camshafts with adapter for angle sensor

-VAS 611 007/5- -E-.
– Hold camshafts via adapter for angle sensor -VAS 611

007/9- and adapter for angle sensor -VAS 611 007/10- -E-
in »0.0°« position with a wrench.

Note
♦ The camshafts tend to turn.

♦ Use a hexagon key to hold the camshafts in 0.0° position.
♦ Always remove the hexagon key after the camshafts have
been tightened.
– Tighten brakes after adjustment has been completed.

– Tighten bolts -a- for brakes to 11 Nm on both sides.
is »red« -C-.
– Display must not be »yellow« or »green«.

– Tighten camshaft adjuster on inlet camshaft to specified ini‐

tial torque ⇒ Fig. ““”“, page 260 .
– Make sure that bolts -a- for brakes are released on both
sides.


is »green« -A-.

– Seal camshaft adjuster -2- using suitable plugs -A- from en‐
gine bung set -VAS 6122-.
– Fit a piece of paper -A- into plugs to catch the engine oil.
– Insert plugs into camshaft adjusters with the open side fac‐
ing towards front, as shown in illustration.
Determining correction angle
– Screw in locking pin -T10340-.


– Read valve timing on display and write down values.
1. measurement example: value reading on display
Note
♦ The correction angle is determined for each individual vehi‐

cle.
♦ The value read after the engine has been cranked is used
for determining the correction angle.
♦ Note the algebraic signs of the values.
♦ The correction angle results from the difference between the
specification and the value which has been read after the
crankshaft has been cranked twice.
♦ The correction angle is used to adjust the valve timing.
♦ The difference between the actual value (read after 2 full
revolutions of the engine) and the specification is calculated.
♦ The result is the correction angle to be set, with the corre‐
sponding algebraic sign/direction of rotation.
Example

Index Explanation
e Inlet camshaft - actual value (after 2 full revolutions
of the engine)
f Inlet camshaft - specification (+/- tolerance)
c Direction of correction (+/-)
d Correction value - correction angle
a Exhaust camshaft - actual value (after 2 full revolu‐
tions of the engine)
b Exhaust camshaft - specification (+/- tolerance)
Angle in ° Inlet camshaft Exhaust camshaft

Specified angle -0.5°±1.5° +1.5°±1.5°
– Set determined correction angle for camshafts.

Setting valve timing with correction angle
– Place a cloth underneath camshaft adjuster to catch any
engine oil which runs out.
– Remove plug taken from engine bung set -VAS 6122- from
camshaft adjuster.
– Remove paper from plugs and camshaft adjusters.
– Clean camshaft adjusters with a cleaning cloth and remove
as much engine oil as possible.
– Loosen camshaft adjuster on inlet side ⇒ page 258 .
– Loosen toothed belt sprocket on exhaust side ⇒ page 278 .
– Loosen camshaft adjuster on exhaust side ⇒ page 273 .
NOTICE

– Make sure that bolts -a- for brakes on test tool -VAS 611
007- are released on both sides.


is »green« -A-.

– Set the two camshafts to the determined correction angle ⇒
page 221 .
– To do this, turn camshafts with adapter for angle sensor

-VAS 611 007/9- and adapter for angle sensor -VAS 611
007/10- -E-.
If the valve timing has been set:
– Tighten bolts -a- for brakes on test tool -VAS 611 007- to
11 Nm on both sides.
– Make sure that brake indicator on display is red -C-.

– Display must not be »yellow« or »green«.


– Tighten toothed belt sprocket of exhaust camshaft to speci‐
fied initial torque ⇒ page 280 .
– Tighten camshaft adjuster of exhaust camshaft to specified
initial torque ⇒ page 280 .
– Release brakes -a- on both sides.


is »green« -A-.

– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
from engine bung set -VAS 6122-.
– Fit a new piece of paper into plugs -A- to catch the engine
oil.
– The plug for the camshaft adjuster -1- on exhaust side must
be pushed in slightly.
– Screw in locking pin -T10340-.


Note
♦ Adjust valve timing as precisely as possible. The settings

must be as close to the specifications as possible.
♦ The valve timing must not be outside the tolerance limits.
– Read valve timing, and compare it with specifications.

Specified angle in °
Inlet camshaft Exhaust camshaft
-1.5° ±1.5° +1.0° ±1.5°
– If the valve timing is not OK, adjust valve timing again ⇒

v2.6 alve timing”, page 216 .
– Unscrew locking pin -T10340-.
– Make sure that brakes on test tool -VAS 611 007- are re‐
leased on both sides.
– Tighten camshaft adjuster on inlet camshaft to specified final
torque ⇒ Fig. ““”“, page 261 .
fied final torque ⇒ page 280 .
– Tighten exhaust camshaft adjuster to specified final torque ⇒
page 268 .
Specified torques
♦ ⇒ o2.2 verview - toothed belt”, page 199

♦ Torque wrench -VAS 6583A-

♦ Counter-hold tool -T10172A-
♦ A
♦ Ring spanner -T10499A-

♦ Insert tool -T10500-
♦ Release tool -T10527/1-

Removing
– Set piston of no. 1 cylinder to “TDC” position. ⇒ p4.7 iston to
TDC position”, page 174
– Remove upper part of toothed belt guard ⇒ a2.3.1 nd instal‐
ling upper toothed belt guard”, page 203 .
– Remove lower toothed belt guard ⇒ a2.3.2 nd installing low‐
er toothed belt guard”, page 204 .
– Loosen plug and securing bolt for camshaft adjuster on inlet
side ⇒ a3.3 nd installing camshaft adjuster”, page 256 .
– Loosen securing bolt of toothed belt pulley on exhaust side
by approx. one turn ⇒ page 278 .
– Loosen securing bolt of camshaft adjuster on exhaust side
Note
♦ If a used toothed belt runs in the opposite direction when it is

refitted, it may break.
♦ Before removing, mark direction of rotation of toothed belt
with chalk or felt-tipped pen for re-installation.
– Loosen securing bolt of tensioning roller -1- using insert tool,

13 mm -T10500-.

– Release tension on tensioning roller at eccentric -2- using

wrench -T10499A-.
– Remove toothed belt.
Bend radius of toothed belt

Note
♦ If the radius/diameter is not reached, the toothed belt could

become damaged.
♦ The toothed belt is made of glass fibre fabric.
♦ Never kink toothed belt!
♦ The bend radius -r- of the toothed belt -2- may therefore
never exceed 25 mm. Approx. half of pulley diameter -1- on
crankshaft ⇒ Fig. ““Bend radius of toothed belt”“, page 230 .
Installing
– Fit toothed belt -1- together with crankshaft pulley -2- onto
crankshaft journal.
• Milled surface of crankshaft sprocket -arrow- must be posi‐

tioned on milled surface of crankshaft stub.
• Contact surface between poly V-belt pulley and crankshaft

toothed belt pulley must be free of oil and grease.



• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
• Retaining lug -arrow- of tensioning roller must engage in
recess in cylinder head.

Fit toothed belt in prescribed sequence:
– Pull toothed belt upwards and fit on idler pulley -1-, tension‐
ing roller -2- and camshaft toothed belt pulleys -3- and -4-.
– Rotate eccentric -2- of tensioning roller using special wrench
-T10499A- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment
window.
– Turn eccentric adjuster back until adjustment indicator is

positioned exactly in adjustment window.
Note
♦ Torque wrench -VAS 6583A- must be used for tightening.

♦ When setting specified torque on torque wrench -VAS
6583A-, length must be entered in torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm

using insert tool -T10500- with torque wrench -VAS 6583A-.

Note
Turning the engine further or running the engine may lead to

slight differences in the position of the adjustment indicator -3-
in relation to the adjustment window. The deviations do not
affect the toothed belt tension or the timing.
– Install lower part of toothed belt guard ⇒ a2.3.2 nd installing

lower toothed belt guard”, page 204 .
– Adjust valve timing ⇒ v2.6 alve timing”, page 216 .
– Tighten exhaust camshaft adjuster to specified final torque.
⇒ page 275
Specified torques:
• ⇒ o1.1 verview - poly V-belt drive”, page 122
• ⇒ o2.1 verview - toothed belt cover”, page 198
• ⇒ o2.2 verview - toothed belt”, page 199
• ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – speci‐
• ⇒ o1.2 verview - camshaft housing”, page 181
• ⇒ o3.1 verview - crankcase breather system”, page 317
• ⇒ o2.1 verview - coolant pump, thermostat”, page 348
• ⇒ o1.1 verview - turbocharger”, page 416
• ⇒ o2.1 verview - charge air system”, page 433
• ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
2.8 Removing toothed belt from camshaft



♦ Ring spanner -T10499A-
♦ Insert tool -T10500-

– Set piston in cylinder no. 1 to TDC position ⇒ p4.7 iston to
– Remove upper part of toothed belt guard ⇒ a2.3.1 nd instal‐
ling upper toothed belt guard”, page 203 .
– Loosen securing bolt of camshaft adjuster on inlet side by
approx. one turn ⇒ a3.3 nd installing camshaft adjuster”,
page 256 .


– Loosen securing bolt of tensioning roller -1- using insert tool,
13 mm -T10500-.
– Release tension on tensioner at eccentric -2- using wrench

-T10499A-.
– Remove toothed belt from camshaft pulleys.
Installing
Bend radius of toothed belt

Note
♦ If the radius/diameter is not reached, the toothed belt could

become damaged.
♦ The toothed belt is made of glass fibre fabric.
♦ Never kink any toothed belts, regardless of whether they are
used or new.
♦ The bend radius -r- of the toothed belt -2- may therefore
never exceed 25 mm. Approx. half of pulley diameter -1- on
crankshaft ⇒ page 237 .
Note

♦ Renew O-ring or plug if damaged ⇒ Electronic parts cata‐
logue.




• Retaining lug -arrow- of tensioning roller must engage in

Fit toothed belt in prescribed sequence:

– Pull toothed belt upwards and fit on idler pulley -1-, tension‐
ing roller -2- and camshaft toothed belt pulleys -3- and -4-.
– Using special wrench 30 mm -T10499A-, turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the
right of adjustment window.

– Turn eccentric adjuster back until adjustment indicator is

positioned exactly in adjustment window.
Note
♦ Torque wrench -VAS 6583A- must be used for tightening.

♦ When setting specified torque on torque wrench -VAS
6583A-, length must be entered in torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.

To do this, use insert tool, 13 mm -T10500- with torque
wrench -VAS 6583A- ⇒ o2.2 verview - toothed belt”, page
199 .
Note
Turning the engine further or running the engine may lead to

slight differences in the position of the adjustment indicator -3-
in relation to the adjustment window. The deviation does not
affect the toothed belt tension or the timing.



– Tighten exhaust camshaft adjuster to specified final torque.
⇒ page 275
Specified torques

3 Valve gear
⇒ o3.1 verview - valve gear”, page 242
⇒ a3.2 nd installing camshaft oil seal”, page 244
⇒ a3.3 nd installing camshaft adjuster”, page 256
⇒ a3.4 nd installing toothed belt pulley”, page 277
⇒ a3.5 nd installing camshaft control valve 1N205”, page 282
⇒ a3.6 nd installing exhaust camshaft control valve 1N318”,
page 283
⇒ a3.7 nd installing valve stem seals”, page 284
3.1 Assembly overview - valve gear

1 - Inlet valve
❑ Do not rework. Only
lapping in is permitted.
❑ Valve dimensions ⇒
d4.3 imensions”, page
297
❑ Checking valve guides
⇒ v4.1 alve guides”,
page 296
2 - Outlet valve
❑ Do not rework. Only
lapping in is permitted.
❑ Valve dimensions ⇒
d4.3 imensions”, page
297
❑ Checking valve guides
⇒ v4.1 alve guides”,
page 296
3 - Cylinder head
4 - Valve stem seal
❑ Renewing ⇒ a3.7 nd
installing valve stem
seals”, page 284
5 - Valve springs
❑ Fitting position ⇒ page
243
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker fingers
page 190
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
9 - Retaining clip
❑ For hydraulic compensation element.
10 - Hydraulic compensation element
❑ Do not interchange
❑ Oil contact surface
Installation position of valve spring
3. Valve gear 243

• The end with smaller diameter -a- must face towards valve
spring plate.
• The end with larger diameter -b- must face towards cylinder
head.
3.2 Removing and installing camshaft oil

seal
⇒ a3.2.1 nd installing camshaft oil seal, for inlet camshaft on
belt pulley side, exhaust side with toothed belt sprocket”, page
244
⇒ a3.2.2 nd installing camshaft oil seal, for inlet camshaft on
belt pulley side, exhaust side with camshaft adjuster”, page 246
⇒ a3.2.3 nd installing camshaft oil seal, for exhaust camshaft on
belt pulley side, exhaust side with toothed belt sprocket”, page
249
⇒ a3.2.4 nd installing camshaft oil seal, for exhaust camshaft on
belt pulley side, exhaust side with camshaft adjuster”, page 251
⇒ a3.2.5 nd installing camshaft oil seal, exhaust camshaft, gear‐
box end ”, page 254
3.2.1 Removing and installing camshaft oil

seal, for inlet camshaft on belt pulley
side, exhaust side with toothed belt
sprocket
♦ Assembly tool -T10478 B-

Removing
– Unscrew bolt -1- and remove camshaft toothed belt pulley.
– Remove seal -1- using extractor hook -T20143/1-.
Installing
Note
– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve
-T10478/2-.
3. Valve gear 245


– Separate fitting sleeve and guide sleeve.
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Draw in seal to stop using thrust piece -T10478/1A- and bolt

-1- for camshaft pulley.
– Install toothed belt (adjust valve timing) ⇒ page 237 .

seal, for inlet camshaft on belt pulley

side, exhaust side with camshaft ad‐

juster
Removing
3. Valve gear 247

Installing
Note
-T10478/2-.

– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.

– Draw in seal to stop using thrust piece -T10478/1A- and bolt

-1- for camshaft pulley.

seal, for exhaust camshaft on belt pul‐
ley side, exhaust side with toothed belt
sprocket
Removing
3. Valve gear 249

Installing
Note
-T10478/2-.

– Fit guide sleeve -T10478/2- with oil seal -1- to camshaft.

– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far

as stop.

seal, for exhaust camshaft on belt pul‐
ley side, exhaust side with camshaft
adjuster
3. Valve gear 251

Removing
– Remove engine support ⇒ a1.6 nd installing engine support”,
page 136 .
Installing
Note
-T10478/2-.


– Fit guide sleeve -T10478/2- with oil seal -1- to camshaft.
– Draw in thrust piece -T10478/1A- to stop using bolt -1- for

camshaft pulley.

– Installing engine support ⇒ a1.6 nd installing engine sup‐
port”, page 136 .
3. Valve gear 253


seal, exhaust camshaft, gearbox end
♦ Assembly tool -T10479B-
Removing
– Remove toothed belt pulley for coolant pump ⇒ a2.7 nd
installing toothed belt pulley for coolant pump”, page 366 .
– Carefully fit extractor hook -T20143/1- between camshaft
and seal -1-.
– Lever out seal.

Installing
– Remove any burrs in the outer area of the grooves in the ex‐
haust camshaft -arrows- using fine sandpaper (220–1000 P).

Note
-T10479/2-.

– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
shaft.
3. Valve gear 255

– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Push seal onto camshaft and unbolt guide sleeve.
– Draw in seal -2- to stop using thrust piece -T10479/1- and
bolt -1- for toothed belt pulley for coolant pump.
– Install toothed belt pulley for coolant pump ⇒ a2.7 nd instal‐

ling toothed belt pulley for coolant pump”, page 366 .
3.3 Removing and installing camshaft ad‐

juster
⇒ a3.3.1 nd installing inlet side camshaft adjuster, exhaust side
with toothed belt sprocket”, page 256
⇒ a3.3.2 nd installing inlet side camshaft adjuster, exhaust side
⇒ a3.3.3 nd installing camshaft adjuster, exhaust side”, page
269
3.3.1 Removing and installing inlet side cam‐

shaft adjuster, exhaust side with tooth‐
ed belt sprocket

♦ Counter-hold tool -T10554/1-
♦ Knurled screws -T10554/2- (not illustrated)

Preparing tools
– Bolt on counter-hold tool -T10172A- and counter-hold tool
-T10554/1- using knurled screws -T10554/2- -arrows-.
Removing
Note
♦ Place a cloth under the camshaft adjuster and tensioning

roller to catch the engine oil which runs out.
♦ The contact points between the toothed belt and compo‐
3. Valve gear 257

Fitting counter-hold tool -T10554-
• The contours of pins -1- and -2- of counter-hold tool -

T10554/1- are not distributed evenly on the bolt circle.
• They correspond to the contour of the bolt circle in the cam‐
shaft adjuster.
Loosening camshaft adjuster on inlet side:

– Fit counter-hold tool -T10554- with counter-hold tool -
T10172A- to camshaft pulley -1- as shown in illustration.
– The pins must be inserted properly into holes -arrows-.
– Fit counter-hold tool -T10554- so that it rests flat against
camshaft adjuster -1-.
– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool -T10172A-.
– Loosen plug -1-, and unscrew it.


T10172A- again, to loosen securing bolt -1- of camshaft
adjuster.
– Loosen bolt -1- of camshaft adjuster -2-.

⇒ a3.4 nd installing toothed belt pulley”, page 277 .
Note
Do not relieve tension from toothed belt, and do not remove

toothed belt from camshafts when adjusting valve timing. Only
loosen camshaft adjuster.
Removing camshaft adjuster of inlet camshaft:

– Detach toothed belt from camshafts.
– Unscrew securing bolt -1- of camshaft adjuster, and remove
– Use a cleaning cloth to remove engine oil from camshaft and
camshaft housing.
Installing
• Camshafts are located in “TDC” position.
• Camshaft pulleys are properly aligned.
• Crankshaft is in “TDC position”.
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Renew O-ring of plug if damaged.
– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
3. Valve gear 259

– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
– Fit toothed belt onto camshafts ⇒ page 237 .
Tightening camshaft adjuster of inlet camshaft to specified initial
torque
Note
♦ If the camshafts are turned when pre-tightening with the

crankshaft fixed in place using the locking pin -T10340-, the
valve timing will be changed.
♦ If the crankshaft is not locked in place, the deviations that
occur when counter holding will be transferred to the crank‐
shaft via the toothed belt.
♦ The valve timing will not be affected in this case.
– Before pre-tightening, unscrew locking pin -T10340-.

– Pre-tighten bolt -1- to specified pre-tightening torque in two
stages.
Stage Securing bolt for camshaft Specified torque

adjuster
1st -1- 18 Nm
2nd -1- 50 Nm


T10172A- and adapter -T10172/1-.
stages.
Stage Securing bolt for toothed Specified torque

belt pulley
1st -1- 18 Nm
2nd -1- 50 Nm
Tightening camshaft adjuster of inlet camshaft to specified final
torque
– Screw locking pin -T10340- back in.
– Tighten bolt -1- for camshaft adjuster to final torque.
Stage Securing bolt for camshaft Angle to turn bolts

adjuster
1st -1- 135°
– Tighten securing bolt for toothed belt pulley on exhaust side
to final specified torque.
3. Valve gear 261

Stage Securing bolt for toothed Angle to turn bolts

belt pulley
1st -1- 90°
– Screw in plug -1-, and tighten it to specified torque.

T10172A- and counter-hold tool -T10554-.
Stage Plug for camshaft adjuster Specified torque
1st -1- 20 Nm
Installing
Note
Make sure to remove the camshaft clamp and the crankshaft

locking pin before cranking the engine.
Specified torques
♦ ⇒ o3.1 verview - crankcase breather system”, page 317
♦ ⇒ a2.6 djustment of assembly mountings (engine and gear‐
box mountings)”, page 117


view - alternator
3.3.2 Removing and installing inlet side cam‐

shaft adjuster, exhaust side with cam‐
shaft adjuster

Preparing tools
3. Valve gear 263

Removing
Note

– Unscrew bolts -arrows- and remove cover from camshaft

adjuster for exhaust camshaft.

shaft adjuster.

NOTICE
Risk of damage to camshaft caused by improper handling.
– Never use the camshaft clamp for counter holding.
Loosening camshaft adjuster on inlet side:

T10172A- to camshaft pulley -1- as shown in illustration.
– The pins must be inserted properly into holes -arrows-.
– Hold camshaft in position using counterhold tool -T10554-
and counterhold tool -T10172A-.
– Loosen plug -1-, and unscrew it.

T10172A- again, to loosen securing bolt -1- of camshaft
adjuster.
3. Valve gear 265

– Loosen bolt -1- of camshaft adjuster -2-.

⇒ a3.3.3 nd installing camshaft adjuster, exhaust side”, page
269 .
Note

Removing camshaft adjuster of inlet camshaft:

– Detach toothed belt from camshafts.
Installing
• The camshaft pulleys are properly aligned with each other.
Note

– Renew bolts -1- and -2- for both camshaft adjusters and
screw them in onto stop.


Tightening camshaft adjuster of inlet camshaft to specified initial
torque
Note


stages.

adjuster, inlet side
1st -1- 18 Nm
2nd -1- 50 Nm
– Hold exhaust camshaft in position using counterhold tool
-T10554- and counterhold tool -T10172A-.
stages.
3. Valve gear 267


adjuster, exhaust side
1st -1- 18 Nm
2nd -1- 50 Nm
Tightening camshaft adjuster to specified final torque

1st -1- 135°
– Tighten securing bolt for camshaft adjuster on exhaust side
-1- to final torque setting.

adjuster
1st -1- 135°


1st -1- 20 Nm
Installing
Note

Specified torques
♦ ⇒ page 128
♦ ⇒ o3.1 verview - crankcase breather system”, page 317
♦ ⇒ o3.1 verview - valve gear”, page 242
3.3.3 Removing and installing camshaft ad‐

juster, exhaust side
Special tools for removing and installing the camshaft adjuster
of exhaust camshaft
3. Valve gear 269

♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /18-
♦ Adapter -10 - 222 A /29-

♦ Adapter -T40093/3-6-

3. Valve gear 271

Preparing tools
Note

– Unscrew bolts -arrows- and remove cover from camshaft

adjuster for exhaust camshaft.



shaft adjuster.
To adjust valve timing:
Detaching camshaft adjuster on exhaust side:
– Insert counterhold -T10554- with counterhold -T10172A- in
holes -arrows-.

– Hold camshaft pulley -2- in place using counterhold -
T10554- and counterhold -T10172A-.
– Loosen bolt -1- one turn.

– Loosen securing bolt for camshaft adjuster on inlet side ⇒
page 258 .
Note

Removing camshaft adjuster of exhaust camshaft:

– Remove engine bracket. ⇒ a1.6 nd installing engine sup‐
port”, page 136
– Detach toothed belt from camshafts ⇒ t2.8 oothed belt from
3. Valve gear 273

– Use a cleaning cloth to remove engine oil from camshaft and

camshaft housing.
Installing
Note

– Renew bolts -1- and -2- for both camshaft adjusters and
screw them in onto stop.

Camshaft adjuster specified final torque
Note


stages.


1st -1- 18 Nm
2nd -1- 50 Nm
– Hold exhaust camshaft in position using counterhold tool
-T10554- and counterhold tool -T10172A-.
stages.

adjuster, exhaust side
1st -1- 18 Nm
2nd -1- 50 Nm
Tightening camshaft adjuster to specified final torque
– Screw locking pin -T10340- back in.
3. Valve gear 275


1st -1- 135°
– Tighten securing bolt for camshaft adjuster on exhaust side
-1- to final torque setting.

adjuster
1st -1- 135°

1st -1- 20 Nm
Installing
Note

Specified torques


view - alternator

pulley

Preparing tools
3. Valve gear 277

Note

♦ Do not relieve tension from toothed belt, and do not remove
toothed belt from camshafts when adjusting valve timing.
Only loosen camshaft adjuster.
Loosen toothed belt pulley for exhaust camshaft
– Removing upper part of toothed belt guard ⇒ a2.3.1 nd in‐

stalling upper toothed belt guard”, page 203 .
– Loosen bolt -1- approx. one turn using counter-hold tool
-T10172A- with adapter -T10172/2- and -T10172/1-.
Remove toothed belt pulley for exhaust camshaft:
– Loosen camshaft adjuster -2- of inlet camshaft ⇒ Fig. ““Loos‐
ening camshaft adjuster on inlet side:”“, page 258 .


– Loosen bolt -1-.
– Detach toothed belt from camshafts. ⇒ t2.8 oothed belt from
camshaft”, page 234
– Unscrew securing bolt -1- of toothed belt pulley, and remove
toothed belt pulley.
Installing
Note

– Renew bolt -1- for camshaft adjuster on inlet side, and screw
it in to stop by hand.
– Renew bolt -2- for toothed belt pulley on exhaust side, and
screw it in to stop by hand.
– Fit toothed belt in position and adjust valve timing ⇒ page
237 .
3. Valve gear 279

Pre-tightening
stages.

adjuster
1st -1- 15 Nm
2nd -1- 50 Nm
stages.
Stage Securing bolt for toothed Specified torque

belt pulley
1st -1- 15 Nm
2nd -1- 50 Nm
Tightening to final specified torque


adjuster
1st -1- 135°
– Tighten securing bolt for toothed belt pulley on exhaust side
to final specified torque.
Stage Securing bolt for toothed Angle to turn bolts

belt pulley
1st -1- 90°

T10172A- and counter-hold tool -T10554-.
1st -1- 20 Nm
Installing
Further assembly is performed in the reverse order of removal.
3. Valve gear 281

Note

Specified torques:
• ⇒ o2.1 verview - toothed belt cover”, page 198
• ⇒ o2.2 verview - toothed belt”, page 199
• ⇒ o3.1 verview - crankcase breather system”, page 317
• ⇒ o2.1 verview - charge air system”, page 433
3.5 Removing and installing camshaft con‐

trol valve 1 -N205-
⇒ a3.5.1 nd installing camshaft control valve 1N205, exhaust
⇒ a3.5.2 nd installing camshaft control valve 1N205, exhaust
side with toothed belt pulley”, page 283
3.5.1 Removing and installing camshaft con‐

trol valve 1 -N205-, exhaust side with
camshaft adjuster
Removing
– Unscrew bolt -4- and remove camshaft control valve 1 -

N205-.
Installing
Note
♦ Check O-ring for damage.

♦ If it is damaged, renew it together with camshaft control
valve 1 -N205-.
♦ The O-ring cannot be renewed individually.
Specified torques

3.5.2 Removing and installing camshaft con‐

trol valve 1 -N205-, exhaust side with
toothed belt pulley
Removing
– Unscrew bolt -2- and remove camshaft control valve 1 -

N205-.
Installing
Note
Renew O-ring.
Specified torques
⇒ o1.2.1 verview - camshaft housing, exhaust side with toothed
belt pulley”, page 181
3.6 Removing and installing exhaust cam‐

shaft control valve 1 -N318-
Installed in vehicles with adjustable exhaust camshaft only.
Removing
– Unscrew bolt -1- and remove exhaust camshaft control valve

1 -N318-.
3. Valve gear 283

Installing
Note
Renew O-ring.
Specified torques
3.7 Removing and installing valve stem

seals
⇒ a3.7.1 nd installing valve stem seals (cylinder head instal‐
led)”, page 284
⇒ a3.7.2 nd installing valve stem seals (cylinder head re‐
moved)”, page 290
3.7.1 Removing and installing valve stem

seals (cylinder head installed)
♦ Spark plug socket -3122 B-
♦ Removal and installation device for valve cotters -VAS

5161A- with guide plate -VAS 5161A/32-32-.
♦ Compressed air adapter -VAS 5161 A/35- (not illustrated)

♦ Valve stem seal fitting tool -3365-
♦ Valve stem pliers -VAS 6770-
exterior; Rep. gr. 50; Plenum chamber bulkhead; Removing
and installing plenum chamber cover.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Assembly overview - bulk‐
head.
– Unscrew bolts -arrows-. Remove heat shield for right drive

shaft.
– Unscrew bolts -arrows-, and remove oil supply line -1-.
3. Valve gear 285

– Remove camshaft housing ⇒ a1.4 nd installing camshaft

housing”, page 190 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
– Remove roller rocker fingers together with compensation el‐

ements and place them on a clean surface.
– Unscrew spark plugs with spark plug socket -3122 B-.
– Unscrew locking pin -T10340-.
– Set piston of respective cylinder to “bottom dead centre”.

– Fit guide plate -VAS 5161A/32- onto cylinder head and se‐
cure with knurled screws -VAS 5161/12-.

– Screw compressed air adapter -VAS 5161 A/35- into the

respective park plug thread hand-tight.
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
• Minimum pressure: 6 bar.
– Insert punch -VAS 5161/3A- into guide plate.
– Use a plastic hammer to knock loose the firmly seated valve

cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161A/32-1- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-2-.
– Attach pressure fork -VAS 5161/2- to toothed piece and
press assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve
cotters and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
• The compressed air hose remains connected.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem pliers -VAS 6770-.
3. Valve gear 287

Note
♦ Risk of damage when installing valve stem seals.

♦ Slowly push valve stem seals as far as stop.
♦ Seal oil passages of cylinder head with a lint-free cloth.
– Lightly oil sealing lip of valve stem seal -A-.
– Carefully press valve stem oil seal -A- onto valve guide us‐
ing valve stem seal fitting tool -3365-.
If the valve cotters have been removed from the assembly
cartridge, they must first be inserted into the insert tool -VAS
5161A/32-3-.

• Larger diameter of valve cotters faces upwards.

– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate. For installation
position of valve spring refer to ⇒ page 243 .
– Bolt guide plate -VAS 5161A/32- onto cylinder head again.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve -

VAS 5161A/32-2- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts
the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Installing
Assemble in reverse order of dismantling. The following should
be observed:
– Install oil supply line -1-, and tighten bolts -arrows- to 9 Nm.
3. Valve gear 289

– Install plenum chamber bulkhead ⇒ General body repairs,

head.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50; Plenum chamber bulkhead; Removing and
installing plenum chamber cover.
– Install spark plugs ⇒ Maintenance; Booklet .
– Install camshaft housing ⇒ a1.4 nd installing camshaft hous‐
ing”, page 190 .
Specified torques
⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; As‐
sembly overview - drive shaft
⇒ General body repairs, exterior; Rep. gr. 50; Plenum chamber
bulkhead; Removing and installing plenum chamber cover
⇒ General body repairs, exterior; Rep. gr. 50; Bulkhead; As‐
sembly overview - bulkhead.
3.7.2 Removing and installing valve stem

seals (cylinder head removed)
♦ Removal and installation device for valve cotters -VAS
5161A- with guide plate -VAS 5161A/32-32-.

♦ Engine and gearbox support -VAS 6095-
♦ Cylinder head tensioning device -VAS 6419-
♦ Valve stem pliers -VAS 6770-
♦ Valve stem seal fitting tool -3365-
3. Valve gear 291

– Remove cylinder head ⇒ a1.3 nd installing cylinder head”,

page 185 .
– Insert cylinder head tensioning device -VAS 6419- into en‐
gine and gearbox support -VAS 6095-.
– 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
chamber from which valve stem seals are to be removed.
– Allow compressed air to flow into air cushion until it lies
against valve disc.
– Fit guide plate -VAS 5161A/32- onto cylinder head and se‐
cure with knurled screws -VAS 5161/12-.
– Insert punch -VAS 5161/3A- into guide plate.

– Use a plastic hammer to knock loose the firmly seated valve
cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.

– Slide sleeve -VAS 5161A/32-1- onto assembly cartridge and

insert cartridge into guide plate -VAS 5161A/32-2-.
– Attach pressure fork -VAS 5161/2- to toothed piece and
press assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve
cotters and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem pliers -VAS 6770-.
Note
♦ Risk of damage when installing valve stem seals.

♦ Slowly push valve stem seals as far as stop.
♦ Seal oil passages of cylinder head with a lint-free cloth.
– Lightly oil sealing lip of valve stem seal -A-.
3. Valve gear 293

– Carefully press valve stem oil seal -A- onto valve guide us‐
ing valve stem seal fitting tool -3365-.
If the valve cotters have been removed from the assembly
cartridge, they must first be inserted into the insert tool -VAS
5161A/32-3-.
• Larger diameter of valve cotters faces upwards.

– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate. For installation
position of valve spring refer to ⇒ page 243 .
– Bolt guide plate -VAS 5161A/32- onto cylinder head again.
– Insert assembly cartridge -VAS 5161A/32-1- with sleeve -

VAS 5161A/32-2- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts
the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.

– Repeat procedure on each valve.

– Install cylinder head ⇒ a1.3 nd installing cylinder head”,
page 185 .
3. Valve gear 295

4 Inlet and exhaust valves

⇒ v4.1 alve guides”, page 296
⇒ v4.2 alves”, page 297
⇒ d4.3 imensions”, page 297
4.1 Checking valve guides

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge -VAS 6079-
Test procedure
– Insert valve in guide. Valve stem end must be flush with

guide. On account of differing stem diameters, only use inlet
valve in inlet valve guide and exhaust valve in exhaust valve
guide.
– Determine rock.
• Wear limit: 0.5 mm.

– If the wear limit is exceeded, repeat the measurement with

new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be exchanged.
4.2 Checking valves

– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.
4.3 Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is

permitted.
Dimension Inlet valve Outlet valve

∅a mm 28.5 25.0
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
4. Inlet and exhaust valves 297

17 – Lubrication
1 Sump, oil pump
⇒ o1.1 verview - sump/oil pump”, page 298
⇒ o1.2 il:”, page 302
⇒ a1.3 nd installing lower part of sump”, page 302
⇒ a1.4 nd installing upper part of sump”, page 308
⇒ a1.5 nd installing oil pump”, page 312
⇒ a1.6 nd installing oil level and oil temperature senderG266”,
page 314
1.1 Assembly overview - sump/oil pump
Note
♦ Metal shavings or a large quantity of small metal particles found during engine repair could indicate
that the 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 cooler and oil filter.
♦ Removing and installing oil spray jets ⇒ a4.3 nd installing oil spray jets”, page 169 .
298 Rep. gr.17 - Lubrication

1 - Nut
❑ 9 Nm
2 - Oil level and oil tempera‐
ture sender -G266-
oil level and oil tem‐
perature senderG266”,
page 314
3 - Seal
4 - Oil drain plug
❑ With captive seal on
new vehicles
❑ To be renewed on 1st
oil change
❑ Oil drain plug with non-
captive seal installed
on first oil change is to
be reused
❑ 30 Nm
5 - Seal
❑ For oil drain plug instal‐
led on 1st oil change
6 - Lower part of sump
lower part of sump”,
page 302
7 - Bolt
❑ 5 Nm +90°
8 - Dowel sleeve
❑ Qty. 2
9 - Cover
❑ For oil pump chain sprocket
10 - Drive chain
❑ For oil pump.
❑ Before removing, mark running direction with paint
11 - Bolt
12 - Upper part of sump
❑ Removing and installing ⇒ a1.4 nd installing upper part of sump”, page 308
❑ Tighten loosened connecting union for oil filter ⇒ Fig. ““Tightening connecting union for oil filter”“, page
300
13 - Baffle plate
14 - Sprocket
❑ For oil pump drive.
1. Sump, oil pump 299

15 - Dowel pin
16 - Oil filter
❑ Remove and install with oil filter tool -3417-
❑ Before installing, lightly coat seal with clean engine oil.
❑ Connecting union for oil filter ⇒ Fig. ““Tightening connecting union for oil filter”“, page 300
❑ 20 Nm
17 - Seal
18 - Sealing plug chain
19 - Oil pump
❑ Removing and installing ⇒ a1.5 nd installing oil pump”, page 312
20 - Bolt
❑ 10 Nm
21 - O-ring
22 - Oil intake tube
❑ Clean strainer if soiled
23 - Bolt
Tightening connecting union for oil filter
• If the connecting union -2- in the top section of sump -1- is

loose, retighten it as described below.
Use only the two nuts -3 and 4- for this procedure.
• Hexagon nut -068 115 723-, qty. 2, ⇒ Electronic Parts Cata‐
logue
– Screw nuts -3- and -4- onto connecting union -2-, and coun‐
terlock them.
– Tighten connecting union -2- using nut -3-.
– Loosen the two nuts and remove them, taking care not to
loosen the connecting union.
Specified torques
Connecting union Specified torque
-2- 50 Nm

Lower part of sump - specified torque and tightening sequence

Stage Bolts Specified torque
2nd -1 … 19- 12 Nm
Upper part of sump - specified torque and tightening sequence
Note

2nd -Arrows- Screw onto stop by hand
3rd -1 … 19- 8 Nm


4th -1 … 19- Turn 90° further
5th -Arrows- Specified torque ⇒ Rep. gr. 34;
Removing and installing gearbox;
Specified torques for gearbox.
1.2 Engine oil:
Note
Oil level must not be above “max.” mark.
Capacities and specifications ⇒ Maintenance; Booklet ; Engine

oil: Capacities and specifications.
Check engine oil level ⇒ Maintenance; Booklet ; Engine oil lev‐
el: Checking.
1.3 Removing and installing lower part of

sump
♦ Wedge -T10383/2-

♦ Cutting tool -T10561-
♦ Applicator gun -VAS 6966-
♦ Protective mat -VAS 531003-

♦ Scraper
♦ Commercially available scraper
♦ Sealant remover
♦ Hand drill with plastic brush
♦ Safety glasses
Cutting tool -T10561-
1- Bolt
2- Washer

3- Bracket
4- Knife
5- Guide
6- Handle
7- Inserts for support (rod) for conversion of handle
8- Bolt
9- Support
Removing
– Drain engine oil.
insulation.
– Remove front right wheel housing liners ⇒ General body
repairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - front wheel housing liner.
– After radiator cowl has been removed, fit protective mat
-VAS 531003- to vehicle as shown in illustration.
– Remove sealing plug chain -2- from sump -1-.


– Loosen and unscrew bolts in the sequence -19 to 1-.
– Loosen 2 bolts on oil sump, but do not unscrew completely.

– Cut through seal between oil sump -4- and engine -1-.
– Use cutting tool -T10561- to do this.
Note
♦ The sump is sealed with liquid sealant -2- ⇒ Electronic parts

catalogue.
♦ When hardened, the sealant has a high adhesive strength.
– Separation is made centrally between bolts -3-.

– Position cutting tool -T10561- on seal -arrows- without it

canting.
– Drive in cutting tool -T10561- -3- using a hammer as far as it
will go -arrow-.
– Do not cant cutting tool -T10561- when doing this.

– Do not cutting tool -T10561- sideways.
– Do not lever with cutting tool -T10561-.
– Perform procedure at other points as described until sump is
detached.
– Use wedge -T10383/2- to further loosen detached positions.
– Using a plastic hammer carefully drive in wedge.
– Drive in wedge -T10383/2- only to same depth as sealing
surface.
– Carefully detach sump (bottom section) from adhesive bond.
– Fit wedge -T10383/2- at another position and detach the
bonded joint in the same way.
– Carefully detach lower part of sump from adhesive bond
using a commercially available scraper.
– Insert suitable screwdriver or assembly lever at position
marked -arrow-.
– Separate oil sump from crankcase.

Installing
Note
♦ Danger of soiling lubrication system.

♦ Cover open parts of engine.
– Spray sealing surface with sealant remover and leave to act.

– Remove sealant residues from sump upper part with a flat
scraper.
CAUTION
Risk of eye injury caused by sealant residue.
– Remove sealant residue from sump (bottom section) using a

rotating plastic brush, for example.
Note

2 mm).

– Apply sealant in a bead -arrow- to clean sealing surface of

bottom section of sump using applicator gun -VAS 6966-.
• Thickness of sealant bead: 2 to 3 mm.
Note
♦ Danger of blocking lubrication system with excess sealant.

♦ Take particular care when applying sealant bead in area of
the sealing flange.
♦ Do not apply sealant bead thicker than specified.
♦ Lower part of oil sump must be installed within 5 minutes
after sealant has been applied.
– Position bottom section of sump and tighten bolts ⇒ page

301 .
– Install oil level and oil temperature sender -G266- ⇒ a1.6 nd
installing oil level and oil temperature senderG266”, page
314 .
Note
Allow sealant to cure for approx. 30 minutes after installing

lower part of sump. Only then fill with engine oil.
– Replenish engine oil, and check oil level ⇒ Maintenance;

Booklet .
Specified torques
♦ ⇒ Fig. ““Lower part of sump - specified torque and tightening
1.4 Removing and installing upper part of

sump

♦ Hand drill with plastic brush

♦ Safety glasses
Removing

conditioner compressor; Removing air conditioner compres‐
sor from and installing to bracket.
– Remove oil pump ⇒ a1.5 nd installing oil pump”, page 312 .
– Unscrew securing bolts -arrows- for gearbox to upper sec‐
tion of sump -1-.

– Carefully detach upper part of sump from adhesive bond.

– Remove baffle plate.
Installing
Note

♦ Renew gaskets, oil seals and self-locking nuts.
– Remove sealant residues from cylinder block with a flat scra‐

per.
CAUTION
Risk of eye injury caused by sealant residue.
– Remove sealant residue from upper part of sump, e.g. with

rotating plastic brush.
– Check oil galleries in upper part of sump and cylinder block

for soiling.

Note

2 mm).
– Apply sealant in a bead -arrow- to clean sealing surface of

bottom section of sump using applicator gun -VAS 6966-.
• Thickness of sealant bead: 2 to 3 mm.
Note

♦ Upper part of oil sump must be installed within 5 minutes
after sealant has been applied.
– Check that dowel pin -2- is securely seated in cylinder block.

– Attach baffle plate -1- to cylinder block.

– Position top section of sump and tighten bolts ⇒ page 301 .
– Install oil pump ⇒ a1.5 nd installing oil pump”, page 312 .
installing air conditioner compressor from and to bracket.
Booklet .
Specified torques
♦ Securing gearbox to engine ⇒ Rep. gr. 34; Removing and
installing gearbox; Installing gearbox
1.5 Removing and installing oil pump

Removing
– Unclip cover for oil pump chain sprocket -arrows-.

– Guide out oil pump with chain sprocket under drive chain.
Installing
– Check that dowel sleeves -1, 3- are fitted in oil pump.
– Fit seal with strainer -2- in oil pump.

– Turn oil pump chain sprocket by hand to check oil pump for
ease of movement.
Note
Renew sluggish oil pump.
– Fit oil pump with chain sprocket into drive chain and secure.
– Install bottom section of sump ⇒ a1.3 nd installing lower part
Booklet .
Specified torques

1.6 Removing and installing oil level and

oil temperature sender -G266-
Removing
– Drain engine oil.
– Undo nuts -1- and remove oil level and oil temperature send‐
er -G266- -item 3-.
Installing
Note
Renew oil seal -4-.

Booklet .
Specified torques

2 Engine oil cooler

⇒ o2.1 verview - engine oil cooler”, page 315
⇒ a2.2 nd installing engine oil cooler”, page 315
2.1 Assembly overview - engine oil cooler
1 - Engine oil cooler

❑ Observe notes ⇒ o1 il
pump”, page 298
engine oil cooler”, page
315
❑ Renew coolant after re‐
placing
2 - Bolt
❑ 8 Nm +90°
3 - Oil seals
2.2 Removing and installing engine oil

cooler
Removing
fold”, page 481 .
– Unscrew bolts -arrows- and detach engine oil cooler -1-.
2. Engine oil cooler 315

Installing
– Insert new O-rings.
page 481 .
Specified torques
♦ ⇒ o2.1 verview - engine oil cooler”, page 315

3 Crankcase ventilation
⇒ o3.1 verview - crankcase breather system”, page 317
⇒ a3.2 nd installing oil separator”, page 318
3.1 Assembly overview - crankcase breather system
1 - Hose
❑ For crankcase ventila‐
tion.
2 - Cover
❑ For oil separator
3 - Oil separator
oil separator”, page 318
4 - O-ring
5 - Union
6 - Hose
tion.
7 - Bolt
❑ Self-locking
tightening sequence: ⇒
page 317
Oil separator - specified torque and sequence
3. Crankcase ventilation 317

– Tighten bolts in the sequence -1 … 9-.

Tighten bolts in the sequence 9 Nm
-1 … 9-.
3.2 Removing and installing oil separator

♦ Applicator gun -VAS 6966-
♦ Scraper
♦ Commercially available studs, M6x20 mm, qty. 2
♦ Sealant remover
Removing
insulation.
– Unscrew bolts -arrow- and push charge air cooling pump
-V188- to one side.
– Pull off crankcase breather hose -3-.

– Release fasteners -2- -arrow- on cover -1- for oil separator

and detach cover.
– Carefully release oil separator from bonded joint.

Installing
Note

– Remove sealant residues from cylinder block with a flat scra‐

per.
– Screw 2 M6x20 mm studs a few turns into holes -arrows-.

Note

2.0 mm).
Note

– Apply bead of sealant -arrow- onto clean sealing surface of

oil separator using applicator gun -VAS 6966- as illustrated.
• Width of sealant bead: 2.0 mm.
The oil separator must be installed within 5 minutes after apply‐
ing the sealant.
– Fit oil separator onto studs -arrows- and push onto crank‐
case.

– Start securing bolts.

– Unscrew studs.
– Install oil separator ⇒ page 317 .
insulation.
Specified torques
♦ ⇒ Fig. ““Oil separator - specified torque and sequence”“,
page 317
♦ ⇒ o2.2 verview - electric coolant pump”, page 351

4 Oil filter, oil pressure switch

⇒ o4.1 verview - oil filter/oil pressure switch”, page 322
⇒ a4.2 nd installing oil pressure switchF1”, page 324
⇒ a4.3 nd installing oil pressure switch for reduced oil pressur‐
eF378”, page 325
⇒ o4.4 il pressure”, page 326
⇒ a4.5 nd installing oil pressure regulating valveN428”, page
328
4.1 Assembly overview - oil filter/oil pressure switch

1 - Oil filter
❑ Remove and install with
oil filter tool -3417-
❑ Before installing, lightly
coat seal with clean en‐
gine oil.
❑ Tighten loosened con‐
necting union for oil fil‐
ter ⇒ Fig. ““Tightening
connecting union for oil
filter”“, page 300
❑ Observe notes ⇒ page
298
❑ 20 Nm
2 - Oil pressure switch for re‐
duced oil pressure -F378-
❑ Switch pressure 0.3 to
0.6 bar
❑ Checking ⇒ o4.4 il
pressure”, page 326
ling oil pressure switch
for reduced oil pressur‐
eF378”, page 325
❑ 20 Nm
Note
♦ The oil pressure switch is fitted

with a captive seal.
♦ The seal is not designed for re‐
peated use.
3 - Seal
4 - O-ring
5 - Valve for oil pressure control -N428-
❑ Removing and installing ⇒ a4.5 nd installing oil pressure regulating valveN428”, page 328
6 - Bolt
❑ 8 Nm
7 - Seal
8 - Oil pressure switch -F1-
❑ Switch pressure 2.15 to 2.95 bar
4. Oil filter, oil pressure switch 323

❑ Checking ⇒ o4.4 il pressure”, page 326
❑ Removing and installing ⇒ a4.2 nd installing oil pressure switchF1”, page 324
❑ 20 Nm
Note
♦ The oil pressure switch is fitted

with a captive seal.
♦ The seal is not designed for re‐
peated use.
4.2 Removing and installing oil pressure

switch -F1-
♦ T-bar and socket, 24 mm -T40175-
Removing
Note
Fit all heat shield sleeves in the same place when installing.

insulation.
– Separate electrical connector -arrow-.
– Place a cloth underneath to catch escaping engine oil.

– Remove oil pressure switch -F1-.

Installing
Note
♦ Renew oil seal after removing.

♦ Screw in new oil pressure switch -F1- immediately in hole to
avoid loss of oil.
– Renew oil seal for oil pressure switch after removal. For
allocation, refer to ⇒ Electronic Parts Catalogue
– Cut old oil seal open to remove it.
– Check oil level ⇒ Maintenance; Booklet .
Specified torques
♦ ⇒ o4.1 verview - oil filter/oil pressure switch”, page 322

switch for reduced oil pressure -F378-
♦ T-bar and socket, 24 mm -T40175-
Removing
– Pull activated charcoal filter solenoid valve 1 -N80- -3- off
intake manifold and push it downwards slightly.

Note
Place a cloth underneath to catch escaping engine oil.
– Unscrew oil pressure switch for reduced oil pressure -F378-

-1-.
Installing
Note
♦ Oil seal must always be renewed after removing.

♦ To avoid loss of oil, Insert new oil pressure switch for re‐
duced oil pressure -F378- immediately into bore.
– Renew oil seal for oil pressure switch after removal. For
allocation, refer to ⇒ Electronic Parts Catalogue
– Cut off seal to replace.
– Check oil level ⇒ Maintenance; Booklet .
Specified torques
4.4 Checking oil pressure

♦ Oil pressure tester -V.A.G 1342-
• Oil level OK. Checking ⇒ Maintenance; Booklet .
• Engine oil temperature at least 80°C (radiator fan must have
run once)
– Remove oil pressure switch for reduced oil pressure -F378-
⇒ a4.3 nd installing oil pressure switch for reduced oil pres‐
sureF378”, page 325 .
– Screw oil pressure tester -V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch for reduced oil pressure -F378-
into hole in oil pressure tester -V.A.G 1342- to seal it.
– Start the engine.

Checking oil pressure at idling speed and at 2000 rpm

• Oil pressure at idling speed: at least 0.6 bar.
• Oil pressure at 2000 rpm: at least 1.5 bar.
– Switch off engine.
Check oil pressure at 3,800 rpm
– Remove electrical connection from oil pressure control valve
-N428- ⇒ page 329 .
– Start the engine.
– Increase engine speed to 3800 rpm.
– Read oil pressure on oil pressure tester -V.A.G 1342-.
• Oil pressure at 3800 rpm: at least 2.8 bar.
If specification is not attained:
– Connect electrical connection to oil pressure control valve
-N428- ⇒ page 329 .
– Interrogate the engine control unit event memory and delete
all event entries ⇒ Vehicle diagnostic tester.
– Check valve for oil pressure control -N428- with ⇒ vehicle
diagnostic tester.
Note
Mechanical damage, e.g. to bearings, could also be the cause

for oil pressure being too low.
If no fault is found:
– Renew oil pump ⇒ a1.5 nd installing oil pump”, page 312 .
Check oil pressure switch for reduced oil pressure -F378-
(brown):
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527B- to battery positive

(+) and oil pressure switch for reduced oil pressure -F378-
(brown) using cables from auxiliary test set -V.A.G 1594C-.
• LED must not light up.
– If LED lights up, renew oil pressure switch for reduced oil
pressure -F378-.
If LED does not light up:

– Start engine: At 0.3 to 0.6 bar the LED must light up, other‐
wise renew oil pressure switch.
Checking oil pressure switch -F1- (blue):
– Switch off engine.
– Connect voltage tester -V.A.G 1527B- to battery positive (+)
and oil pressure switch -F1- (blue) using cables from auxili‐
ary test set -V.A.G 1594C-.
• LED must not light up.
– If LED lights up, renew oil pressure switch oil pressure
switch -F1-.
If LED does not light up:
– Remove electrical connection from oil pressure control valve
-N428- ⇒ page 329 .
– Start engine and increase rpm: At pressure of 2.15 to 2.95
bar LED must light up, otherwise renew oil pressure switch.
– Connect electrical connection to oil pressure control valve
-N428- ⇒ page 329 .
– Install oil pressure switch for reduced oil pressure -F378- ⇒
a4.3 nd installing oil pressure switch for reduced oil pressur‐
eF378”, page 325 .
– Interrogate the engine control unit event memory and delete
all event entries ⇒ Vehicle diagnostic tester.
Specified torques

regulating valve -N428-
Removing
Note
Attach all heat-shielding sleeves in the same places when in‐

stalling.

insulation.
– Remove right drive shaft from gearbox, raise and tie ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40; Drive shaft; Remov‐
ing and installing drive shaft.
Vehicles with front-wheel drive:
– Detach heat-shield sleeve from electrical connector -3-.

A - Vehicles with front-wheel drive

B - Vehicles with all-wheel drive
– Place a cloth underneath to catch escaping engine oil.
– Unscrew bolt -2-, and pull off valve for oil pressure control
-N428- -1-.
Installing
– Observe allocation and installation position of valve for oil
pressure control -N428-.
– Renew O-ring.
insulation.
Specified torques

19 – Cooling
1 Cooling system/coolant
⇒ d1.1 iagram - coolant hoses”, page 330
⇒ c1.2 ooling system for leaks”, page 332
⇒ a1.3 nd adding coolant”, page 340
1.1 Connection diagram - coolant hoses

⇒ d1.1.1 iagram – coolant hoses, CC, Golf Cabriolet, Scirocco,
Sharan and Tiguan”, page 330
⇒ d1.1.2 iagram - coolant hoses, T-Roc 2018, Golf 2020, Golf
Estate 2021”, page 331
1.1.1 Connection diagram – coolant hoses, CC, Golf Cabriolet, Scirocco, Shar‐
an and Tiguan
Note
♦ The arrows point in the direction of coolant flow.

♦ The arrows on the coolant pipes and on the ends of the hoses must be aligned with each other.
330 Rep. gr.19 - Cooling

1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 336
3 - Cylinder head/cylinder
block
placing
4 - Engine preheating element
-Z97-
❑ Depending on vehicle
5 - Turbocharger
6 - Integrated exhaust mani‐
fold
7 - Heat exchanger for heater
placing
8 - Radiator outlet coolant -
G62-
9 - Coolant pump
❑ With thermostat hous‐
ing
11 - Radiator outlet coolant
temperature sender -G83-
12 - Radiator for engine cool‐
ant
placing
13 - Charge air cooling pump -V188-
14 - Radiator for charge air cooling circuit
❑ Renew coolant after replacing
15 - Charge air cooler in intake manifold
16 - Auxiliary heater
❑ Optional equipment
1.1.2 Connection diagram - coolant hoses, T-Roc 2018, Golf 2020, Golf Estate
2021
Note
♦ The arrows point in the direction of coolant flow.

♦ The arrows on the coolant pipes and on the ends of the hoses must be aligned with each other.
1. Cooling system/coolant 331

1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 339
3 - Cylinder head/cylinder
block
placing
4 - Turbocharger
5 - Integrated exhaust mani‐
fold
6 - Heat exchanger for heater
placing
7 - ATF cooler
G62-
9 - Coolant pump
❑ With thermostat hous‐
ing
12 - Radiator for engine coolant
15 - Charge air cooler in intake manifold
1.2 Checking cooling system for leaks

⇒ c1.2.1 ooling system for leaks, Golf Cabriolet 2012 >, CC
2012 >, Tiguan 2008 >, Scirocco 2015 >, Sharan 2016 >”, page
332
⇒ c1.2.2 ooling system for leaks, Golf 2020 >, Golf Estate 2021
>, T-Roc 2018 >”, page 336
1.2.1 Checking cooling system for leaks,

Golf Cabriolet 2012 >, CC 2012 >, Ti‐
guan 2008 >, Scirocco 2015 >, Sharan
2016 >

♦ Adapter for cooling system tester -V.A.G 1274/8-
♦ Cooling system tester -V.A.G 1274 B-
Note
To perform the leakage test correctly, first run a self-test on the

cooling system tester -V.A.G 1274 B-.

Self-test of cooling system tester -V.A.G 1274 B-
– Operate cooling system tester -V.A.G 1274 B- several times.

– Build up a pressure of 3.0 bar on cooling system tester.
– Observe pressure on pressure gauge of cooling system test‐

er 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
CAUTION
– Open cap -1- on coolant expansion tank.

• Engine at operating temperature.

– Fit cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/8- to coolant expansion tank.
– Using hand pump, build up a pressure of approx. 1.5 bar.

• The pressure must not drop by more than 0.2 bar within
10 minutes.
– If pressure drops by more than 0.2 bar, locate leaks and
rectify faults.
Note
♦ A pressure drop of 0.2 bar within 10 minutes is caused by

the coolant cooling down.
♦ The colder the engine, the lower the pressure loss.
♦ If necessary, repeat the check while the engine is cold.

Check pressure relief valve in cap.

V.A.G 1274/9- onto coolant filler cap.
– Build up pressure using hand pump of cooling system tester.
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
1.2.2 Checking cooling system for leaks,

Golf 2020 >, Golf Estate 2021 >, T-Roc
2018 >
♦ Cooling system tester -V.A.G 1274 B-

Note
To perform the leakage test correctly, first run a self-test on the

cooling system tester -V.A.G 1274 B-.
Self-test of cooling system tester -V.A.G 1274 B-
– Operate cooling system tester -V.A.G 1274 B- several times.

– Build up a pressure of 3.0 bar on cooling system tester.
– Observe pressure on pressure gauge of cooling system test‐

er 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.
Prerequisites for check
• Engine at operating temperature.

Test sequence:
CAUTION
– Carefully open filler cap -arrow- of coolant expansion tank.

V.A.G 1274/8- to coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx.

1.5 bar.
• The pressure must not drop by more than 0.2 bar within
10 minutes.
– If pressure drops by more than 0.2 bar, locate leaks and
rectify faults.

Note
♦ A pressure drop of 0.2 bar within 10 minutes is caused by

the coolant cooling down.
♦ The colder the engine, the lower the pressure loss.
♦ If necessary, repeat the check while the engine is cold.
Check pressure relief valve in cap.
Note
The cap may have a different shape depending on the model

year.
– Screw cap -1- into adapter for cooling system tester -V.A.G
1274/9- -2-.
– Connect adapter for cooling system tester -V.A.G 1274/9- to

cooling system tester -V.A.G 1274 B- using connecting hose
supplied.
– Build up pressure using hand pump of cooling system tester.
Blue cap
♦ The pressure relief valve must open at a pressure of 1.4 bar.
Black cap
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.
Cap with indication of overpressure
• The opening pressure is specified on the top of this cap

Overpressure in bar Tolerance

kPa
1st 1 kPa 0.01 bar ---
ex‐
am‐
ple
2nd 140 kPa 1.4 bar 0.2 bar
ex‐
am‐
ple
3rd 160 kPa 1.6 bar 0.2 bar
ex‐
am‐
ple
Continued for all versions
• If the pressure relief valve opens prematurely:
– Renew cap.
1.3 Draining and adding coolant

♦ Refractometer -T10007B-

♦ Hose clamp pliers -VAS 6340-
♦ Cooling system charge unit -VAS 6096-
♦ Safety glasses
♦ Safety gloves
Draining
– Open filler cap -arrow- for coolant expansion tank.

CAUTION

insulation.
– Disconnect connector -2- on radiator outlet coolant tempera‐
ture sender -G83-.
– Pull out retaining clip -3-, and remove lower right coolant
hose from radiator.
– Drain coolant.
– Lift retaining clip -arrow-, and disconnect lower right coolant
hose from radiator for charge air cooling circuit.
– Drain remaining coolant.

Filling

Note
♦ The water used for mixing has a major influence on the

effectiveness of the coolant. Because the water quality dif‐
fers from country to country and even from region to region,
the quality of the water to be used in the cooling system
has been specified 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
corrosion 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 ad‐
ditives.
♦ Because of its high boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries
with tropical climates.
♦ The refractometer -T10007A- or refractometer -T10007B-
must be used to determine the current anti-freeze value.
♦ The scale -1- of the refractometer is calibrated for the cool‐

ant additives G12++ and G12evo.
♦ The scale -2- of the refractometer is calibrated for the cool‐
ant additive G13.
♦ If it is not possible to ensure that the same type of coolant
additive is filled: always determine anti-freeze protection us‐
ing the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a
minimum and, in countries with arctic conditions, down to
approx. -36°C. Increasing the frost protection is permissible
only if climatic conditions require stronger frost protection. It
may, however, be increased only to a maximum of -48°C.
Otherwise, the cooling effect will be impaired.

♦ Do not reduce the coolant concentration by adding water

even in warmer seasons and in warmer countries. Frost pro‐
tection must be guaranteed down to at least -25°C.
♦ The temperature read off the refractometer corresponds to
the »ice flocculation point«. Flakes of ice may start forming
in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

Frost Coolant additive Coolant ad‐ Distilled wa‐
protection to concentration 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.
• Coolant: ⇒ Electronic Parts Catalogue.
– Connect coolant hoses with plug-in connectors to radiator ⇒
page 388 .
– Fill spare container for cooling system charge unit -VAS
6096/1- of cooling system charge unit -VAS 6096- with at
least 10 litres of pre-mixed coolant.
– Make sure to use correct mixing ratio.

– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank -1-.
– Install cooling system charge unit -VAS 6096- to adapter
-V.A.G 1274/8-.
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it. Col‐
lect coolant in the container.

– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.
• The suction-jet pump reduces pressure in the cooling sys‐

tem to below atmospheric pressure.
• The needle on the gauge should move into the green zone.
– In addition, briefly open valve -A- (turn lever in direction of
flow to do this) so that hose of canister -VAS 6096- fills with
coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• The suction-jet pump will continue generating a vacuum in
the cooling system.
• The needle on the gauge must remain in the green zone.
– Close valve -B-.
• The needle on the gauge must stay in the green zone.
• The low pressure in the cooling system is then sufficient for
subsequent filling.
Note
♦ If the needle does not reach the green zone, repeat the
process.
♦ If the vacuum drops, the cooling system must be checked for
leaks.
– Pull off compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the coolant expansion tank of -VAS 6096-; the
cooling system is then filled.
– Remove cooling system charge unit -VAS 6096- from cool‐
ant expansion tank.
– Fill coolant up to max. mark.


insulation.
– On vehicles with auxiliary heater, switch on auxiliary heater
for about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in the button must not light up.
– Tighten cap of coolant expansion tank until it engages.
– Start engine and run alternately at approx. 1500 rpm to max‐
imum of 2800 rpm until radiator fan starts operating.
– Switch off engine and let it cool off.
– Check coolant level.
– Screw adapter for cooling system tester -V.A.G 1274/8-

again onto expansion tank.
– Use cooling system tester -V.A.G 1274 B- to apply a pres‐
sure of 1 bar to the cooling system.
– Use tester to relieve pressure and remove cooling system
tester -V.A.G 1274 B-.
– With the engine running, fill coolant up to approx. 5 mm
above max. mark.
• When the engine is cold, the coolant level must be between
the min. and the max. markings.
• The coolant level can be at or above the max. mark when
the engine is at operating temperature.

2 Coolant pump, regulation of cooling

system
⇒ o2.1 verview - coolant pump, thermostat”, page 348
⇒ o2.2 verview - electric coolant pump”, page 351
⇒ o2.3 verview - coolant temperature sender”, page 352
⇒ a2.4 nd installing electric coolant pump”, page 354
⇒ a2.5 nd installing coolant pump”, page 356
⇒ a2.6 nd installing thermostat”, page 362
⇒ a2.7 nd installing toothed belt pulley for coolant pump”, page
366
⇒ a2.8 nd installing coolant temperature senderG62”, page 367
⇒ a2.9 nd installing radiator outlet coolant temperature send‐
erG83”, page 370
2.1 Assembly overview - coolant pump, thermostat

1 - Thermostat housing
thermostat”, page 362
2 - Thermostat
❑ For cylinder block cool‐
ant circuit
❑ Up to 07.2016: Starts to
open at approx. 87°C
❑ From 07.2016 onwards:
Starts to open at ap‐
prox. 97°C
❑ Different versions
⇒ Electronic parts cata‐
logue
thermostat”, page 362
3 - Seal
4 - Coolant pump
coolant pump”, page
356
❑ Renew toothed belt as
well when renewing
coolant pump
5 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt
by hand to ensure it
is screwed into old
thread. Then tighten
bolt to specified torque
6 - Seal
❑ Ensure proper seating of seal
❑ Lightly coat with coolant before installing.
7 - Toothed belt guard
❑ For toothed belt for coolant pump
8 - Bolt
❑ 20 Nm +90°
9 - Toothed belt
10 - Crankshaft
11 - Bolt
2. Coolant pump, regulation of cooling system 349

❑ 8 Nm
12 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified
torque.
13 - Cover
❑ For thermostat
14 - Seal
15 - Thermostat
❑ For main coolant circuit (radiator)
❑ Up to 11.2012: Starts to open at approx. 80°C
❑ As of 11.2012: Starts to open at approx. 87°C
❑ Removing and installing ⇒ a2.6 nd installing thermostat”, page 362
❑ Fitting position ⇒ page 350
16 - Bolt
Installation position of thermostat for large cooling circuit
• Must be positioned with centring pin in guide -arrow- in ther‐

mostat housing.
Thermostat housing to coolant pump - specified torque and
sequence
– Tighten bolts in sequence -A … F-.

Bolts Specified torque

-A … F- 8 Nm
Cover for thermostat to thermostat housing - specified torque
– Tighten securing bolts for cover -1- in sequence -A to D-.

Securing bolts for Specified torque
cover -1-
-A … D- 7 Nm
2.2 Assembly overview - electric coolant pump

1 - Charge air cooling pump

-V188-
❑ with holder
electric coolant pump”,
page 354
2 - Coolant hose
3 - Bolt
❑ 8 Nm
4 - Coolant hose
2.3 Assembly overview - coolant tempera‐

ture sender
⇒ o2.3.1 verview – coolant temperature sender, CC, Golf Cab‐
riolet, Scirocco, Sharan and Tiguan”, page 352
⇒ o2.3.2 verview - coolant temperature sender, T-Roc 2018 >,
Golf 2020 >, Golf Estate 2021 >”, page 353
2.3.1 Assembly overview – coolant temperature sender, CC, Golf Cabriolet,

Scirocco, Sharan and Tiguan

1 - Retaining clip
❑ Check for firm seating
2 - O-ring
ling radiator outlet cool‐
ant temperature send‐
erG83”, page 370
4 - Electrical connector
❑ For coolant tempera‐
ture sender -G62-.
G62-
ling coolant tempera‐
ture senderG62”, page
367
6 - O-ring
❑ Moisten with coolant
7 - Support ring
❑ Included with coolant
temperature sender -
G62- ⇒ Electronic parts
catalogue.
8 - Bolt
❑ 4 Nm +45°
2.3.2 Assembly overview - coolant temperature sender, T-Roc 2018 >, Golf
2020 >, Golf Estate 2021 >

1 - Bolt
❑ 8 Nm
G62-
ling coolant tempera‐
ture senderG62”, page
367
3 - O-ring
4 - Support ring
❑ Included with coolant
temperature sender -
G62- ⇒ Electronic parts
catalogue.
5 - Retaining clip
❑ Check for firm seating
6 - O-ring
radiator outlet coolant temperature senderG83”, page 370
2.4 Removing and installing electric cool‐

ant pump
♦ Hose clamps to 25 mm -3094-

Removing
CAUTION

insulation.


– Clamp off coolant hoses on charge air cooling pump -V188-
using hose clamps up to 25 mm -3094-.
– Release hose clip -3- and remove coolant hose.
– Unscrew bolt -2- and remove charge air cooling pump -
V188-.
Installing
Note
Secure all hose connections with hose clips corresponding to

production standard ⇒ Electronic parts catalogue.

insulation.
– Check coolant level ⇒ page 347 .
Specified torques
2.5 Removing and installing coolant pump




Removing
charcoal filter.

– Unscrew bolts -arrows- and remove crankcase breather

hose.
– Lay wiring harness to one side -arrows-.
– Unscrew bolts -1, 3- and remove cover -2- for toothed belt
for coolant pump.
– Move clear electrical wiring harness -1- and coolant hose
-2-.
– Release hose clips -arrows-, and disconnect all coolant ho‐

ses from coolant pump.

– Detach coolant pump with toothed belt.

– Remove thermostat housing if coolant pump is being re‐
newed ⇒ a2.6 nd installing thermostat”, page 362 .
Installing
Install in reverse order of removal. Observe the following:
Note
♦ Secure hose connections with hose clips meeting production

standard ⇒ Electronic parts catalogue.
♦ Always adhere to the sequence of work steps given below
when installing the coolant pump.
♦ This ensures that the toothed belt is correctly tensioned.
♦ The following work steps must be carried out with the aid of
a 2nd mechanic.
– Renew gasket for housing -arrows-.
– Ensure proper seating of gaskets -arrows-.

– Renew toothed belt of coolant pump ⇒ Item 9 (page 349) .
– Lubricate seal for coolant pump lightly with coolant.
– Set No. 1 cylinder to TDC ⇒ v2.5 alve timing”, page 213 .
– Fit toothed belt so that it is centred and move coolant pump
into installation position.
– Mount coolant pump on cylinder head with securing bolts.
– Pre-tighten bolts in the specified sequence:


2nd -1 … 5- 10 Nm
– Loosen all bolts again by one turn.
– Fit torque wrench -VAS 6583A- with hexagon socket
(10 mm) -item 6- to coolant pump.
– Using hexagon on coolant pump, preload coolant pump in

clockwise direction to 30 Nm using 10 mm hexagon socket
-6-, extension and torque wrench -VAS 6583A-.
– For ease of use, fit torque wrench -VAS 6583A- on vertically.
Note
♦ Do not support torque wrench with your other hand.

♦ To ensure the poly V-belt is not over-tensioned, do
not »push the torque wrench again« after the specified tor‐
que has been achieved.
♦ Have a second mechanic tighten securing bolts -2-, -1- and
-5-.
♦ In the meantime, you keep the torque wrench -VAS 6583A-
set to specified torque.
– Pre-load coolant pump.

– While doing so, have a second mechanic pre-tighten coolant
pump securing bolts in anti-clockwise direction, starting with
bolts -2-, -1- and -5- (»stage 3«).
• By tightening securing bolts -2-, -1- and -5- to specified tor‐
que, the desired belt tension is reached.

• After securing bolts have been tightened initially, torque

wrench -VAS 6583A- can be removed.
– Then tighten securing bolts (»4th stage«).
3rd -2, 1, 5- 10 Nm
4th -3, 4, 5, 1, 2- 12 Nm
Coolant hose schematic diagram ⇒ d1.1 iagram - coolant ho‐
ses”, page 330 .
Specified torques
♦ Tightening sequence for coolant pump ⇒ page 360
♦ ⇒ d1.1 iagram - coolant hoses”, page 330 .
- battery
2.6 Removing and installing thermostat

⇒ a2.6.1 nd installing thermostat for main coolant circuit (radia‐
tor)”, page 362
⇒ a2.6.2 nd installing thermostat for cylinder block coolant cir‐
cuit”, page 365
2.6.1 Removing and installing thermostat for

main coolant circuit (radiator)

♦ Special wrench -T10508-

Removing
– Release hose clip -4- and detach coolant hose -3-.
– Remove bolts -arrows- and detach cover -2- from thermostat

housing.
– Remove thermostat using special wrench -T10508-.

– Slightly push down special wrench -T10508- and turn it in

-direction of arrow- while doing so.
Installing
– Insert thermostat ensuring that the centring pin of thermostat
is seated in guide -arrow-.
– Install thermostat using special wrench -T10508-.
– Slightly push down special wrench -T10508- and turn it to

stop in -direction of arrow- while doing so.
Note
Renew seals.
– Moisten gasket with coolant.


Specified torques
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - speci‐
2.6.2 Removing and installing thermostat for

cylinder block coolant circuit
Removing
page 356 .
– Unscrew bolts in the sequence -F to A-.
– Detach coolant pump from thermostat housing.

– Detach thermostat -2- from coolant pump -1-.
Installing
Note
Renew seals.
– Moisten gasket with coolant.

– Fit thermostat housing onto coolant pump.

• Centring pins on thermostat must be fitted in guides -arrows-

on coolant pump.
– Tighten bolts for thermostat housing ⇒ page 350 .
page 356 .
Specified torques
♦ ⇒ Fig. ““Thermostat housing to coolant pump - specified tor‐
que and sequence”“, page 350

pulley for coolant pump
Removing
page 356 .
– Loosen bolt -1- using counterhold -T10172A- with adapters
-T10172/2-.

– Unscrew bolt and remove toothed belt pulley -2-.

Installing
– Fit toothed belt pulley:
• The grooves -1- and -2- in the camshaft are arranged asym‐
metrically.
• Cut-outs -arrows- in toothed belt pulley are also arranged
asymmetrically.
– Fit toothed belt pulley onto camshaft so that the asymmet‐
rical notches of the camshaft are fully centred within the
cut-outs of the toothed belt pulley.
page 356 .
Specified torques
2.8 Removing and installing coolant tem‐

perature sender -G62-


Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler
cap -1- on coolant expansion tank briefly and then close cap
again (it should click into place).
– Release and pull off connector on coolant temperature send‐

er -G62-.
– Place a cloth underneath to catch escaping coolant.

– Unscrew bolt -1-, and pull off coolant temperature sender
-G62- -2-.
– If O-ring -3- with support ring -4- remains lodged in cylinder
head, lift out O-ring with support ring using a piece of wire.
– Renew O-ring.
– Insert new coolant temperature sender -G62- immediately
into cylinder head in order to avoid loss of coolant.

Specified torques
♦ ⇒ o2.3 verview - coolant temperature sender”, page 352
2.9 Removing and installing radiator outlet

coolant temperature sender -G83-
⇒ a2.9.1 nd installing radiator outlet coolant temperature send‐
erG83, Sharan, CC and Tiguan”, page 370
erG83, Golf Cabriolet and Scirocco”, page 371
erG83, T-Roc 2018 >, Golf 2020 >, Golf Estate 2021 >”, page
372
2.9.1 Removing and installing radiator out‐

let coolant temperature sender -G83-,
Sharan, CC and Tiguan
Removing
• Engine cold.

insulation.
– Pull out retaining clip -2- and remove radiator outlet coolant
temperature sender -G83- -3-.
– Renew O-ring.

– Insert new radiator outlet coolant temperature sender -G83-

immediately into connection to avoid loss of coolant.
– Install front noise insulation ⇒ General body repairs, exterior;
insulation.
Specified torques
2.9.2 Removing and installing radiator out‐

let coolant temperature sender -G83-,
Golf Cabriolet and Scirocco
Removing
• Engine cold.

insulation.
– Pull out retaining clip -3-, and pull off radiator outlet coolant
temperature sender -G83-.
– Renew O-ring.


insulation.
Specified torques
2.9.3 Removing and installing radiator outlet

coolant temperature sender -G83-, T-
Roc 2018 >, Golf 2020 >, Golf Estate
2021 >
♦ Removal tool -T10498-
Removing
• Engine cold.
– Briefly open cap of coolant expansion tank -arrow- to release
residual pressure in cooling system, then tighten again until
cap engages.


insulation.
– Place a cloth underneath to catch any escaping coolant.

– Pull off retaining clip -3- and pull radiator outlet coolant tem‐
perature sender -G83- out of connection.
Installing
– Renew O-ring.
insulation.

3 Coolant pipes
⇒ o3.1 verview - coolant pipes”, page 374
⇒ a3.2 nd installing coolant pipes”, page 374
3.1 Assembly overview - coolant pipes
1 - Coolant hose
2 - Coolant pipe
❑ Clipped onto intake
manifold (bottom)
❑ To remove, remove in‐
take manifold ⇒ a4.2 nd
installing intake mani‐
fold”, page 481
3 - Bolt
❑ 8 Nm
4 - Coolant hose
5 - Coolant hose
6 - Coolant line
manifold (top)
7 - Coolant hose
8 - Coolant hose
3.2 Removing and installing coolant pipes


Removing
CAUTION
– Clamp off coolant hoses on coolant pipe using hose clamps

up to 25 mm -3094-.
3. Coolant pipes 375

– Release hose clips -arrows- and detach coolant hoses.

fold”, page 481 .
– Lay intake manifold -1- on the workbench as shown.
– Place e.g. a block of wood -2- under the intake manifold as

an underlay.
Note
To avoid damaging the intake manifold and coolant pipe, this

procedure must be carried out very carefully!
– Insert a flat-blade screwdriver into the slot -arrow 1-.

– Carefully push the flat-bade screwdriver in

-direction of arrow 2- and lift the coolant pipe -4- in
-direction of arrow 3- until it comes free from the retainer.
– Continue to lift the coolant pipe -1- in -direction of arrow-
until it comes free of the retainer -2-.
Installing
– First push the coolant pipe onto the mounting -1- until it
engages.
– Then push the coolant pipe onto the mounting -2- until it
engages.
– Check that the coolant pipe has properly engaged by pulling
on it.
3. Coolant pipes 377


Note
♦ Renew seals and O-rings.

to production standard ⇒ Electronic parts catalogue.

page 481 .
Specified torques

4 Radiator, radiator fan

⇒ o4.1 verview - radiator/radiator fan”, page 379
⇒ o4.2 verview - radiator cowl and radiator fan”, page 388
⇒ a4.3 nd installing radiator”, page 392
⇒ a4.4 nd installing water radiator for charge air cooling circuit”,
page 399
⇒ a4.5 nd installing radiator cowl”, page 407
⇒ a4.6 nd installing radiator fanV7”, page 413
4.1 Assembly overview - radiator/radiator

fan
⇒ o4.1.1 verview - radiator and radiator fan, Golf Cabriolet, CC
and Tiguan”, page 379
⇒ o4.1.2 verview - radiator/radiator fan, Sharan”, page 381
⇒ o4.1.3 verview - radiator/radiator fan, Scirocco”, page 384
⇒ o4.1.4 verview - radiator/radiator fan, T-Roc 2018 >, Golf
2020 >, Golf Estate 2021 >”, page 386
4.1.1 Assembly overview - radiator and radiator fan, Golf Cabriolet, CC and
Tiguan
4. Radiator, radiator fan 379

1 - Bolts
❑ For condenser
❑ 5 Nm
2 - Condenser
ling ⇒ Heating, air con‐
ditioning; Rep. gr. 87;
Refrigerant circuit; Re‐
moving and installing
condenser
3 - Radiator for charge air
cooling circuit
ling water radiator for
charge air cooling cir‐
cuit, Golf Cabriolet, CC,
Scirocco and Tiguan”,
page 399
4 - Radiator mounting
5 - Refrigerant line
❑ To condenser
6 - O-ring
❑ For refrigerant line
7 - Rubber mounting
❑ Bottom of radiator in
lock carrier
8 - O-ring
❑ Connection, radiator for
cuit
9 - Retaining clip
❑ Connection for coolant hose, charge air cooler
10 - Coolant hose
❑ On radiator for charge air cooling circuit
❑ Lift retaining clip to remove
❑ Connect ⇒ page 381
11 - Retaining clip
12 - Radiator outlet coolant temperature sender -G83-
❑ Removing and installing ⇒ a2.9 nd installing radiator outlet coolant temperature senderG83”, page 370
13 - O-ring
14 - Coolant hose
15 - O-ring
❑ Connection, radiator

16 - Retaining clip
17 - Bolts
❑ 5 Nm
18 - Radiator for engine coolant
❑ Removing and installing ⇒ a4.3 nd installing radiator”, page 392
19 - Coolant hose
Note
The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
Connecting coolant hose with plug-in connector
– Remove old O-ring -2- in coolant hose -3-.

– Moisten new O-ring with coolant and insert into coolant
hose.
– Push coolant hose into connection -1- until it audibly engag‐
es.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
4.1.2 Assembly overview - radiator/radiator fan, Sharan

1 - Air duct
❑ Secured to lock carrier.
2 - Air duct
❑ Attached to radiator ⇒
page 383
3 - Condenser
ling ⇒ Heating, air con‐
ditioning; Rep. gr. 87;
Refrigerant circuit; Re‐
moving and installing
condenser
4 - Bolt
❑ 6 Nm
5 - Radiator for charge air
cooling circuit
ling water radiator for
cuit, Sharan”, page 402
6 - Lower radiator mounting
❑ For water radiator for
cuit
ant
ling radiator, Sharan”,
page 394
8 - Radiator mounting
❑ The radiator mounting
will be reused when reinstalling the radiator. It will then be bolted to lock carrier. Bolts ⇒ Electronic
Parts Catalogue (ETKA)
9 - Bolt
❑ Qty. 4
❑ 6 Nm
10 - O-ring
11 - O-ring
12 - O-ring
13 - Coolant hose
❑ Connection diagram ⇒ d1.1 iagram - coolant hoses”, page 330
❑ To water radiator for charge air cooling circuit

14 - Coolant hose
❑ To water radiator for charge air cooling circuit
15 - Coolant hose
16 - Coolant hose
17 - O-ring
– Remove old O-ring -2- in coolant hose -3-.

– Moisten new O-ring with coolant and insert into coolant
hose.
es.
Installation position of air ducts

4.1.3 Assembly overview - radiator/radiator fan, Scirocco


ant
radiator”, page 392
placing
2 - Coolant connection
❑ Pull out retaining clip to
remove
3 - Retaining clip
4 - O-ring
❑ Renew
erG83”, page 370
remove
7 - O-ring
remove
9 - Rubber mounting
11 - Rubber mounting
12 - Bolt
❑ 5 Nm
13 - Bolt
❑ 5 Nm
14 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit; Removing and
installing condenser
15 - O-ring
16 - O-ring

❑ Pull out retaining clip to remove
19 - Bolt
❑ 5 Nm
– Check seal -2- for damage, and renew it if necessary.

– Moisten O-ring with coolant, and insert it into coolant hose.
es.
4.1.4 Assembly overview - radiator/radiator fan, T-Roc 2018 >, Golf 2020 >,
Golf Estate 2021 >


ant
radiator”, page 392
placing
2 - Coolant hose
remove
❑ Connect ⇒ Fig. ““Con‐
necting coolant hose
with plug-in connec‐
tor”“, page 388
3 - Retaining clip
4 - O-ring
erG83”, page 370
6 - O-ring
7 - Coolant hose
remove
❑ Connect ⇒ Fig. ““Con‐
necting coolant hose
with plug-in connector”“, page 388
8 - O-ring
9 - Coolant hose
❑ Connect ⇒ Fig. ““Connecting coolant hose with plug-in connector”“, page 388
10 - Air duct
❑ Not fitted in all vehicles
11 - Air duct
❑ For radiator
14 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit; Removing and
installing condenser

❑ For radiator
16 - O-ring
17 - Coolant hose
❑ Connect ⇒ Fig. ““Connecting coolant hose with plug-in connector”“, page 388
18 - O-ring
– Check seal -2- for damage, and renew it if necessary.

– Moisten O-ring with coolant, and insert it into coolant hose.
es.
4.2 Assembly overview - radiator cowl and

radiator fan
⇒ o4.2.1 verview - radiator cowl and radiator fan, Golf Cabriolet,
CC and Tiguan”, page 388
⇒ o4.2.2 verview - radiator cowl and radiator fan, Sharan”, page
389
⇒ o4.2.3 verview - radiator cowl and radiator fan, Scirocco”,
page 390
⇒ o4.2.4 verview - radiator cowl and radiator fan, T-Roc 2018 >,
Golf 2020 >, Golf Estate 2021 >”, page 392
4.2.1 Assembly overview - radiator cowl and radiator fan, Golf Cabriolet, CC
and Tiguan

1 - Radiator cowl
radiator cowl”, page
407
2 - Bolt
❑ Radiator cowl to radia‐
tor
❑ 5 Nm
3 - Bolt
tor
❑ Specified torque: ⇒
o4.1 verview - radia‐
tor/radiator fan”, page
379
4 - Radiator fan 2 -V177-
radiator fanV7”, page
413
5 - Radiator fan -V7-
413
6 - Bracket
❑ Coupling point
7 - Bolt
tor
❑ Specified torque: ⇒
o4.1 verview - radia‐
tor/radiator fan”, page 379
8 - Bolt
❑ 5 Nm
4.2.2 Assembly overview - radiator cowl and radiator fan, Sharan


413
413
3 - Radiator cowl
407
4 - Washer
5 - Bolt
❑ 5 Nm
6 - Bolt
❑ 5 Nm
7 - Washer
4.2.3 Assembly overview - radiator cowl and radiator fan, Scirocco

1 - Coolant hose
2 - Coolant hose
❑ Connection diagram
for coolant hoses ⇒
d1.1 iagram - coolant
hoses”, page 330
3 - Clip
4 - Connector
❑ For coolant shortage in‐
dicator sender -G32-.
5 - Cap
❑ Check using cooling
system tester -V.A.G
1274 B- and adapter for
cooling system tester -
V.A.G 1274/9-
❑ Pressure relief valve
must open at between
1.4 and 1.6 bar
6 - Bolt
❑ 5 Nm
❑ Qty. 2
7 - Expansion tank
8 - Radiator cowl
407
❑ with radiator fan -V7-
and radiator fan 2 -
V177-
9 - Bolt
❑ 5 Nm
❑ Qty. 4
❑ Removing and installing ⇒ a4.6.2 nd installing radiator fanV7 and radiator fan 2V177, Scirocco”, page
414
❑ Removing and installing ⇒ a4.6.2 nd installing radiator fanV7 and radiator fan 2V177, Scirocco”, page
414
12 - Lower coolant hose
❑ Connection diagram for coolant hoses ⇒ d1.1 iagram - coolant hoses”, page 330
13 - Upper coolant hose
❑ Connection diagram for coolant hoses ⇒ d1.1 iagram - coolant hoses”, page 330
14 - Nut
❑ 10 Nm
❑ Qty. 6
15 - Radiator/cooler
❑ After renewing, renew entire coolant.

4.2.4 Assembly overview - radiator cowl and radiator fan, T-Roc 2018 >, Golf
2020 >, Golf Estate 2021 >
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
407
413
4.3 Removing and installing radiator

⇒ a4.3.1 nd installing radiator, Golf Cabriolet, CC, Scirocco and
Tiguan”, page 392
⇒ a4.3.2 nd installing radiator, Sharan”, page 394
⇒ a4.3.3 nd installing radiator, T-Roc 2018 >, Golf 2020 >, Golf
Estate 2021 >”, page 396
4.3.1 Removing and installing radiator, Golf

Cabriolet, CC, Scirocco and Tiguan

Removing
page 407 .
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.

– Unscrew radiator securing bolts -arrows- and remove radia‐
tor -1- downwards.
Installing
observed:
– Install radiator cowl ⇒ a4.5 nd installing radiator cowl”, page
407 .
– Fill with new coolant ⇒ page 347 .
Specified torques
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 379

♦ ⇒ o4.2 verview - radiator cowl and radiator fan”, page 388
4.3.2 Removing and installing radiator, Shar‐

an
Removing
ing”, page 472 .
page 407 .
– Remove guide section -1- on lock carrier -2-. To do this,
unscrew bolts -arrows-.
– Detach guide section from air duct -3-.

– Detach top coolant hose from radiator -arrow-.
– To do this, release retaining clip -arrow- upwards.

– Unbolt retainer for refrigerant lines at top of radiator.

– To do this, unscrew bolt.

– Release catches -arrows- for radiator mountings on left and
right, or pinch them off using side cutters.
Note
The radiator mounting will be reused when reinstalling the radi‐

ator. It will then be bolted to lock carrier. For bolts, refer to
– Push radiator at top slightly towards rear.

– Remove air duct on left and right from condenser.
– Press catches -1- on both sides in -direction of arrow A- to

release them.
– Pull off condenser upwards in -direction of arrow B-.
– Secure condenser to lock carrier.
– Unbolt radiator -2- from charge air cooler -1-.

– To do this, unscrew bolts -5-.

– Secure charge air cooler to lock carrier.
– Remove radiator downwards.
Installing
Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;
Assembly overview - bumper cover
4.3.3 Removing and installing radiator, T-

Roc 2018 >, Golf 2020 >, Golf Estate
2021 >
Removing
insulation.
page 407 .
– Open retainers for refrigerant lines -arrows-.
– Push refrigerant lines to one side.



– Release locking tabs -arrow- for radiator on left and right.

Then pull top of radiator backwards.
– To release, push a suitable screwdriver -A- from behind be‐

tween radiator for engine coolant -2- and radiator for charge
air cooling circuit -1-.

– Position screwdriver -A- as shown but do not lever when

doing so.
– Lift coolant radiator upwards off charge air cooling circuit
radiator.
– Pull radiator out of mountings at bottom.
– Remove radiator downwards.
Installing
observed:
Note
If there are minor dents in the fins, refer to respective instruc‐

tions ⇒ r3.7 adiator and condensers”, page 7 .
– Check O-rings for damage, and renew them if necessary.

– Insert radiator into mounting at bottom. Engage radia‐
tor/cooler with one another. Ensure proper engagement by
pulling.
407 .
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“, page 388 .
Specified torques

4.4 Removing and installing water radiator

for charge air cooling circuit
⇒ a4.4.1 nd installing water radiator for charge air cooling cir‐
cuit, Golf Cabriolet, CC, Scirocco and Tiguan”, page 399
cuit, Sharan”, page 402
cuit, T-Roc 2018 >, Golf 2020 >, Golf Estate 2021 >”, page 403
4.4.1 Removing and installing water radiator

for charge air cooling circuit, Golf Cab‐
riolet, CC, Scirocco and Tiguan

Note
♦ Hose connections are secured with spring-type clips. In case

of repair, only use spring-type clips.
♦ Hose clip pliers -VAS 6340- are recommended to install
spring-type clips.
♦ When installing coolant hoses, route tension-free so that
they do not come into contact with other components (ob‐
serve markings on coolant connection and hose).
– Remove noise insulation or skid plate ⇒ General body re‐

pairs, exterior; Rep. gr. 66; Noise insulation; Assembly over‐
view - noise insulation.
– Remove radiator cowl with radiator fan ⇒ a4.5 nd installing
radiator cowl”, page 407 .
– Removing radiator ⇒ a4.3.1 nd installing radiator, Golf Cab‐
riolet, CC, Scirocco and Tiguan”, page 392 .
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Lift retaining clip -arrow-, and remove upper right hose from
water radiator for charge air cooling circuit.

– Undo and remove coolant pump bolts -arrows- of the radia‐

tor support.
– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier.
Note
Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.

– Pull bottom of radiator for charge air cooling circuit out of
mounting.
– Remove radiator for charge air cooling circuit downwards.

Installing
observed:
Specified torques
Threaded connection on 5 Nm
lock carrier
Assembly overview - bumper cover

for charge air cooling circuit, Sharan
Removing
page 407 .
– Remove radiator -2- ⇒ a4.3.2 nd installing radiator, Sharan”,
page 394 .
– Remove coolant hoses -3- and -4- on charge air cooler -1-.
– To do this, release retaining clips.

Note
If there are minor dents in the fins, refer to ⇒ r3.7 adiator and
condensers”, page 7 .
– Renew O-rings after removal.

Specified torques


Removing and installing bumper cover
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview - lock carrier

for charge air cooling circuit, T-Roc
2018 >, Golf 2020 >, Golf Estate 2021
>
Removing
page 407 .
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Remove centre guide profile -A- from lock carrier -arrows-.
– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows-.

Note
The radiator mounting will be reused when reinstalling the radi‐

ator. It will then be bolted to lock carrier. For bolts, refer to
– Release catches -arrows- of radiator mounting on left and

right, or pinch them off using side cutters. Push radiator at
top slightly towards engine.
– Unclip air duct -2- on left and right.
– Release left and right catches -arrow A-, and detach con‐
denser -3- upwards from water radiator for charge air cooling
circuit -1-.

– Tie up condenser on lock carrier.

– Lift water radiator for charge air cooling circuit -1- at bottom
out of radiator mountings -arrows-.
– Remove both radiators.

– If necessary, detach radiator from radiator for charge air
cooling circuit.
– To do this, release catches -arrow-.

Installing
Note
If there are minor dents in the fins, refer to respective instruc‐

tions ⇒ r3.7 adiator and condensers”, page 7 .
– Check O-rings for damage, and renew them if necessary.

– Insert radiator for charge air cooling circuit -1- at bottom into
radiator mountings -arrows-.

– Attach radiator to radiator for charge air cooling circuit.

– Fit radiator mountings -1- on left and right onto radiator.
When doing so, note the installation position -arrow-.
– Swing water radiator for charge air cooling circuit into lock
carrier. Ensure proper seating of radiator mountings in lock
carrier.
– Use bolts -arrows- to secure radiator mountings, whose
catches have been pinched off, to lock carrier. For bolts,
refer to ⇒ Electronic parts catalogue (ETKA).
• Specified torque: 5 Nm
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Removing and installing bumper
cover.


407 .
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“, page 388 .
Specified torques
4.5 Removing and installing radiator cowl

⇒ a4.5.1 nd installing radiator cowl with radiator fan, CC and
Tiguan”, page 407
⇒ a4.5.2 nd installing radiator cowl with radiator fan, Golf Cab‐
riolet and Scirocco”, page 409
⇒ a4.5.3 nd installing radiator cowl with radiator fan, Sharan”,
page 410
⇒ a4.5.4 nd installing radiator cowl, T-Roc 2018 >, Golf 2020 >,
Golf Estate 2021 >”, page 411
4.5.1 Removing and installing radiator cowl

with radiator fan, CC and Tiguan
Removing
– Release hose clip -3-, and pull air hose -2- off air filter hous‐
ing.

– Unscrew bolts -4- on both sides.

– Unclip air duct -1- from front end by releasing locking lugs
-arrows-, and remove it.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Separate electrical connectors.
– Remove bolts -1- at top.
Note
The left bolt is located below the coolant union.

insulation.
– If fitted, unclip coolant hoses from retainers.
– Release connector -arrow- and pull off.
– Unscrew bolts -2- from below, and remove radiator cowl

downwards.
Installing
Specified torques


with radiator fan, Golf Cabriolet and
Scirocco
Removing
– Release hose clip -1- and detach air intake hose.
– Unclip upper part of intake air duct -2-, and remove it.
– Unclip lower part of intake air duct, and remove it.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Separate electrical connectors.

insulation.
– If fitted, unclip coolant hoses from retainers.
– Remove bolts -1- at top.


– Unscrew bolts -2- from below, and remove radiator cowl
downwards.
Installing
Specified torques

with radiator fan, Sharan
Removing
Removing
ing.


insulation.
– Release and pull off connector -4-.
– Open retainer -3-, and detach coolant hose.

– Release locking lugs on top right and left in
– Pull off radiator cowl -1- upwards, and remove it.
Installing
Specified torques
4.5.4 Removing and installing radiator cowl,

T-Roc 2018 >, Golf 2020 >, Golf Estate
2021 >

Removing
insulation.
– Remove air duct on lock carrier ⇒ a3.3 nd installing air guide
on lock carrier”, page 474 .
CAUTION
Risk of injury to hands caused radiator fan which may start
automatically at any time.
– Do not reach into radiator fan when disconnecting connec‐
tor.
– Using a suitable tool, release radiator cowl together with

radiator fan from locking device.
– Simultaneously press locking tabs on left and right of radia‐

tor cowl.

– Pull radiator cowl together with radiator fan upwards out of

mountings, and remove downwards.
Note
Installing
– Observe electrical connections and routing ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Specified torques
4.6 Removing and installing radiator fan -

V7-
⇒ a4.6.1 nd installing radiator fanV7 and radiator fan 2V177,
Golf Cabriolet, Sharan, CC and Tiguan”, page 413
⇒ a4.6.2 nd installing radiator fanV7 and radiator fan 2V177,
Scirocco”, page 414
⇒ a4.6.3 nd installing radiator fanV7, T-Roc 2018 >, Golf 2020
>, Golf Estate 2021 >”, page 414
4.6.1 Removing and installing radiator fan

-V7- and radiator fan 2 -V177-, Golf
Cabriolet, Sharan, CC and Tiguan
Removing
CAUTION
tor.

page 407 .
– Unscrew bolts -1-, and remove radiator fan -V7-.

– Unscrew bolts -2-, and remove radiator fan -V177-.

Installing
407 .
Specified torques
4.6.2 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-, Scirocco
Removing
CAUTION
tor.

page 407 .
– Move clear lines -1-.
– Unscrew nuts -arrows-, and remove fans.

407 .
Specified torques
4.6.3 Removing and installing radiator fan -

V7-, T-Roc 2018 >, Golf 2020 >, Golf
Estate 2021 >

Removing
Note
Reinstall all cable ties in the same locations when installing.

page 407 .
CAUTION
tor.
– Disconnect electrical connector.
– Unscrew bolts -arrows- and remove radiator fan -V7-.

Installing
407 .
Specified torques

21 – Turbocharging/supercharging
1 Turbocharger
⇒ o1.1 verview - turbocharger”, page 416
⇒ a1.2 nd installing turbocharger”, page 420
⇒ a1.3 nd installing charge pressure positionerV465”, page 426
⇒ a1.4 nd installing connection for turbocharger”, page 429
1.1 Assembly overview - turbocharger

⇒ o1.1.1 verview - turbocharger, version 1”, page 416
⇒ o1.1.2 verview - turbocharger, version 2”, page 417
⇒ o1.1.3 verview - lines on turbocharger”, page 419
1.1.1 Assembly overview - turbocharger, version 1
416 Rep. gr.21 - Turbocharging/supercharging

1 - Turbocharger
stalling turbocharger”,
page 420
2 - Bolt
❑ 8 Nm
3 - Connection
4 - O-ring
5 - Seal
6 - Heat shield
7 - Bolt
❑ 25 Nm
8 - Bolt
❑ 8 Nm
9 - Nut
❑ 14 Nm
10 - Bolt
❑ 9 Nm
11 - Retaining clip
12 - Operating lever
13 - Lock nut
❑ Secure with sealing
paint
❑ 6 Nm
14 - Charge air pressure controller -V465-
Note
♦ Note the following when instal‐

ling!
♦ There may be different types of
charge air pressure controllers
installed.
❑ Removing and installing ⇒ a1.3 nd installing charge pressure positionerV465”, page 426
1.1.2 Assembly overview - turbocharger, version 2
1. Turbocharger 417
1 - Bolt
❑ 25 Nm
2 - Bolt/nut
❑ 8 Nm
3 - Heat shield
4 - Turbocharger
stalling turbocharger”,
page 420
5 - Nut
❑ Renew
❑ 14 Nm
6 - Retaining clip
❑ Renew
7 - Operating lever
8 - Control rod
9 - Lock nut
❑ 6 Nm
❑ Secure with sealing
paint
10 - Retaining clip
❑ Renew
11 - Operating lever
12 - Bolt
❑ Qty. 3 ⇒ Electronic
parts catalogue (ET‐
KA).
❑ 8 Nm +45°
Note
If one ore more of the bolts are

loose, always renew all 3 bolts
13 - Charge air pressure controller -V465-
Note
♦ Note the following when instal‐

ling!
♦ There may be different types of
charge air pressure controllers
installed.
❑ Removing and installing ⇒ a1.3 nd installing charge pressure positionerV465”, page 426
14 - Bolt
❑ 8 Nm
15 - Union
❑ Removing and installing ⇒ a1.4 nd installing connection for turbocharger”, page 429
16 - O-ring

❑ Renew
17 - Seal
❑ Renew
1.1.3 Assembly overview - lines on turbocharger
1. Turbocharger 419
1 - Oil return line

2 - O-ring
3 - Bolt
❑ 9 Nm
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - Oil supply line
7 - O-ring
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 5 Nm
10 - O-ring
❑ If damaged, renew
crankcase breather
hose ⇒ Item 11 (page
420)
11 - Hose
tion.
12 - Bolt
❑ 5 Nm
13 - O-ring
❑ If damaged, renew crankcase breather hose ⇒ Item 11 (page 420)
14 - Turbocharger
❑ Removing and installing ⇒ a1.2 nd installing turbocharger”, page 420
15 - Seal
16 - Coolant lines
❑ Supply and return
17 - Bolt
❑ 8 Nm
18 - O-ring
19 - Bolt
❑ 9 Nm
1.2 Removing and installing turbocharger


♦ Socket Torx T 30 -T10405-
♦ Open jaw socket tool AF13 -V.A.G 1331/14-

♦ Socket/bit set -VAS 6928-
1. Turbocharger 421
Removing
Note
♦ Fit all heat shield sleeves in the same place when installing.
♦ If a mechanical fault is discovered on the turbocharger (e.g.
a destroyed compressor impeller), it is not sufficient to just
renew the turbocharger. To avoid any subsequent damage,
the following work must be carried out:
♦ Check air filter housing, air filter element and air inlet hoses
for contamination.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the
charge air cooler.

charcoal filter.

hose.
Note
Risk of chemical damage to the coolant pump gasket caused by

oil entering between the coolant pump and the cylinder head.
– Cover coolant pump with a cloth.

Vehicles with 3 coolant lines:
– Release hose clip -2- and detach coolant hose.

side.
Vehicles with 2 coolant lines:

side.
– Unscrew bolts and nuts -arrows- and remove heat shield -1-.
Vehicles with front-wheel drive:
– Remove heat shield for drive shaft ⇒ Running gear, axles,
steering; Rep. gr. 40; Drive shaft; Removing and installing
drive shaft heat shield.
1. Turbocharger 423

– Remove bolt -1- and nuts -arrows- and tie up catalytic con‐
verter.
– If fitted, remove centre underbody cladding ⇒ General body

repairs, exterior; Rep. gr. 66; Underbody cladding; Overview
of fitting locations - trims.
– Unscrew bolts -arrows- of bracket.
– Remove bracket.
– Detach heat-shield sleeve from electrical connector -4-.

– Release and pull off electrical connector -4- on oil pressure
switch for reduced oil pressure -F378-.
– Lay cloth around flange of oil lines.

– Remove bolts -arrows- and detach oil supply line -1- and oil
return line -2-.
– Unscrew lower bolt for oil supply line -1- using T 30 Torx
socket -T10405-.
– Disconnect exhaust system. ⇒ e1.2 xhaust pipes from si‐
lencers”, page 546
– Unscrew nuts -arrows- and remove turbocharger.

Installing
– Insert screwdriver -2- in recess -arrow- on turbocharger.
– Lever out seal -1-.

– Renew seals, O-rings and securing nuts of cylinder head.
– Renew clamps for attaching catalytic converter to turbo‐
charger.
– When installing, align screw-type clip on catalytic convert‐
er/turbocharger in such a way that the bolt is accessible with
a torque wrench.
– Fill turbocharger with engine oil at connection for oil supply
line.
– Secure all hose connections with hose clips corresponding
– After installing turbocharger, run engine for about 1 minute
at idling speed to ensure that oil is supplied to turbocharger.
– For electrical connections and routing refer to ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
1. Turbocharger 425

If a new turbocharger with charge pressure positioner has been
installed:
– Adapt engine control unit -J623- to charge pressure position‐
er -V465- using ⇒ Vehicle diagnostic tester.
– Select 0001 - Adaption of charge pressure posi-
tioner V465 .
Specified torques
1.3 Removing and installing charge pres‐

sure positioner -V465-
⇒ a1.3.1 nd installing charge pressure positionerV465, version
1”, page 426
⇒ a1.3.2 nd installing charge pressure positionerV465, version
2”, page 428
1.3.1 Removing and installing charge pres‐

sure positioner -V465-, version 1
Note
♦ Different versions of charge pressure positioner have been

installed.
♦ They have different securing points.
♦ Before installing, visually check which version applies for the
purposes of repair.
Removing
insulation.
– If fitted, remove heat shield for right drive shaft ⇒ Running
gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and
installing drive shaft heat shield.

– Pull off securing clip -2- using locking tool -T40265-.

– Remove bolts -arrows- and detach charge pressure position‐
er -V465-.
Installing
Always renew securing bolts and the securing clip.
Note
There may be different types of charge air pressure controllers

installed.
Charge air pressure controller without adjustable linkage

er -V465- using ⇒ Vehicle diagnostic tester; “Guided func‐
tions”.
– Switch on ignition and select the following menu options on
vehicle diagnostic tester:
♦ 0001 - Adaption charge pressure positioner V465
Charge air pressure controller with adjustable linkage
– Fit thread of charge pressure positioner -V465- at central
position in joint element.
– Adjust charge pressure positioner -V465- ⇒ Vehicle diagnos‐
tic tester.
♦ 0001 - Setting charge pressure positioner V465
– Adjust to specified value by turning linkage. For specified
value, see ⇒ Vehicle diagnostic tester.
– Tighten lock nut to 6 Nm and secure with sealing paint.
Specified torques
1. Turbocharger 427
1.3.2 Removing and installing charge pres‐

sure positioner -V465-, version 2
Note
♦ Different versions of charge pressure positioner have been

installed.
♦ They have different securing points.
♦ Before installing, visually check which version applies for the
purposes of repair.
Removing
insulation.
– If fitted, remove heat shield for right drive shaft ⇒ Running
gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and
installing drive shaft heat shield.
– Pull off securing clips -3-, and remove operating lever -4-.

– Disconnect connector -2-, and remove charge pressure posi‐
tioner -V465- -1-.
Installing
Always renew securing bolts and the securing clip.
Note
There may be different types of charge air pressure controllers

installed.

Charge air pressure controller without adjustable linkage

er -V465- using ⇒ Vehicle diagnostic tester; “Guided func‐
tions”.
♦ 0001 - Adaption charge pressure positioner V465
Charge air pressure controller with adjustable linkage
– Fit thread of charge pressure positioner -V465- at central
position in joint element.
– Adjust charge pressure positioner -V465-: ⇒ Vehicle diag‐
nostic tester
♦ 0001 - Setting charge pressure positioner V465
– Adjust to specified value by turning linkage. For specified
value, see ⇒ Vehicle diagnostic tester.
– Tighten lock nut to 6 Nm and secure with sealing paint.
Specified torques
1.4 Removing and installing connection for

turbocharger
♦ Socket Torx T 30 -T10405-
1. Turbocharger 429
♦ Torque wrench -VAS 6854-
♦ Ratchet insert 1/4" -VAS 6234-

– Release and pull off electrical connectors -1- on coolant tem‐
Vehicles with charge pressure sender -V465-, version 1:

– Release and pull off connectors -2- on charge pressure
sender -V465- .

Vehicles with charge pressure sender -V465-, version 2:
– Release and pull off connectors -2- on charge pressure

sender -V465- .
– Lay wiring harness to one side.
– Open hose clip -1- and push coolant hose -2- to one side.
– Remove bolts -arrows- and detach connection -1-.
Installing:
1. Turbocharger 431
Note
♦ Renew seals, O-rings and securing nuts of cylinder head.

♦ Before installing, lightly moisten O-rings with clean engine
oil.
Specified torques

2 Charge air system

⇒ o2.1 verview - charge air system”, page 433
⇒ a2.2 nd installing charge air cooler”, page 435
⇒ a2.3 nd installing charge pressure senderGX26”, page 438
⇒ c2.4 harge air system for leaks”, page 439
⇒ a2.5 nd installing air pipe”, page 441
2.1 Assembly overview - charge air system
Note
Before performing any checks or any repair work, make sure that all air pipes, air hoses and vacuum lines
are firmly seated and leak-tight.
2. Charge air system 433

1 - O-ring
❑ Before installing, light‐
ly moisten O-ring with
clean engine oil
2 - Union
3 - O-ring
❑ Before installing, light‐
ly moisten O-ring with
clean engine oil
4 - Air intake pipe
air pipe”, page 441
5 - Charge air pressure send‐
er -GX26-
❑ Consisting of
Charge pressure sender
-G31-
Intake air temperature

sender -G42-
charge pressure send‐
erGX26”, page 438
6 - O-ring
❑ Not available separate‐
ly
❑ If damaged, renew
charge pressure sender
-GX26-
7 - O-ring
❑ Before installing, lightly moisten O-ring with clean engine oil
8 - Bolt
❑ Thread-cutting
torque
❑ 7 Nm
9 - Retaining clip
❑ For air intake pipe
10 - Throttle valve module -GX3-
❑ Consisting of
Throttle valve module -J338-
Throttle valve drive for electronic power control -G186-
Throttle valve drive angle sender 1 for electronic power control -G187-
❑ Removing and installing ⇒ a4.3 nd installing throttle valve moduleGX3”, page 484

11 - Seal
12 - Intake manifold
Removing and installing ⇒ a4.2 nd installing intake manifold”, page 481
13 - Seal
❑ Renew
14 - Sealing lip
❑ Before installing, moisten lightly with clean engine oil.
15 - Coolant hose
16 - Clip
17 - Charge air cooler
❑ Removing and installing ⇒ a2.2 nd installing charge air cooler”, page 435
❑ Change coolant after renewing
18 - Bolt
❑ Thread-cutting
torque
❑ 15 Nm
19 - Coolant hose
20 - Clip
21 - Coolant hose
22 - Clip
23 - Bolt
❑ Specified torque and tightening sequence ⇒ o4.1 verview - intake manifold”, page 478
24 - O-ring
❑ Renew
25 - Intake manifold sender -GX9-
❑ Consisting of
Intake air temperature sender 2 -G299-
Intake manifold pressure sender -G71-

❑ Removing and installing ⇒ a5.1 nd installing intake manifold senderGX9”, page 487
26 - Seal
❑ Qty. 4
2.2 Removing and installing charge air

cooler

Removing
page 407 .
– Open clip -1- and push hose -arrow- to one side.
– Disconnect connector -1-.

– Remove air conditioner compressor from bracket -arrows-,

and secure it on vehicle ⇒ Heating, air conditioning; Rep.
– Clamp off coolant hose on charge air cooler with hose clips,
up to 25 mm -VAS 3094-.
– Release hose clip -1- and remove coolant hose.

– Pull charge air cooler -1- evenly towards front (in
-direction of arrow-) out of intake manifold.
Installing
– Fit sealing lip -1- in -direction of arrow- onto charge air cool‐
er -2-.

– Insert new gasket into groove on intake manifold.

– Tighten bolts -arrows- alternately and diagonally working
from centre outwards.
– Install hose clips -1-.
Note

407 .
Specified torques
♦ ⇒ Heating, air conditioning system; Rep. gr. 87; Air condi‐
tioning compressor; Removing and installing air conditioning
compressor from bracket
2.3 Removing and installing charge pres‐

sure sender -GX26-
Charge pressure sender -GX26- consists of:
♦ Charge pressure sender -G31-
♦ Intake air temperature sender -G42-

Removing

– Release fasteners -arrows-, and remove charge pressure
sender -GX26-.
Installing
Note
♦ Renew O-ring.
♦ If the retaining tabs broke off during removal, the sender
can be mounted using two securing bolts ⇒ Electronic parts
catalogue.
Specified torques
Charge pressure sender - 3 Nm
GX26-
2.4 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687-
charcoal filter.

Note
Risk of chemical damage to coolant pump seal from oil ingress

between coolant pump and cylinder head.

hose.
– Seal opening in turbocharger with suitable bung from engine
bung set -VAS 6122-.
– Connect adapter -V.A.G 1687/15- with adapter -V.A.G
1687/11- to turbocharger.
– Connect hose -1- of charge air system tester -V.A.G 1687-

to adapter.
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.
– Connect charge air system tester -V.A.G 1687- to com‐
pressed air -1- via commercial adapter.
Note
If there is water in inspection glass, drain via drain screw -6-.
– Open valve -3-.

• Risk of damage because pressure is set too high.
• The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.
– Check charge air system for leaks.
Methods of testing:
♦ listening
♦ feeling
♦ Leak detection spray
♦ Ultrasonic tester -V.A.G 1842S-
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester -V.A.G 1842S- ⇒ operating
instructions
♦ Before removing the adapter, release pressure in the test
circuit by pulling off hose coupling.
Note
Renew seal and O-rings.
Specified torques
2.5 Removing and installing air pipe




– Release and pull off connector -arrow- of charge pressure
sender -GX26- -1-.
Sharan, Tiguan and T-Roc:

ing.
Golf Cabriolet, Scirocco and CC:
– Release spring-type clips -3-, and remove intake hose -1-.

– Release fasteners -arrows- using release tools -T10527- and

-T10527/1-.
– Remove air pipe -1-.

24 – Mixture preparation - injection

1 Injection system
⇒ o1.1 f fitting locations - injection system”, page 444
1.1 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment
444 Rep. gr.24 - Mixture preparation - injection


valve 1 -N205-
1N205”, page 282
2 - Lambda probe 1 before
catalytic converter -GX10-
❑ Consisting of
Lambda probe -G39-
Lambda probe heater -
Z19-
ling Lambda probe 1
before catalytic conver‐
terGX10”, page 531
3 - Lambda probe 1 after cat‐
alytic converter -GX7-
❑ Consisting of
Lambda probe after cat‐
alytic converter -G130-
Lambda probe 1 heater

after catalytic converter
-Z29-
ling Lambda probe 1
after catalytic conver‐
terGX7”, page 533
4 - Charge air pressure con‐
troller -V465-
ling ⇒ a1.3 nd installing charge pressure positionerV465”, page 426
5 - Engine control unit -J623-
❑ Fitting location: plenum chamber
❑ Removing and installing ⇒ c6 ontrol unit”, page 495
6 - Radiator outlet coolant temperature sender -G83-
❑ Removing and installing ⇒ a2.9 nd installing radiator outlet coolant temperature senderG83”, page 370
⇒ Item 7 (page 445)
❑ Removing and installing ⇒ a1.4.1 nd installing Hall senderG40”, page 584
❑ Consisting of
1. Injection system 445

9 - Charge air pressure sender -GX26-

❑ Consisting of
Charge pressure sender -G31-
Intake air temperature sender -G42-

❑ Removing and installing ⇒ a2.3 nd installing charge pressure senderGX26”, page 438
10 - Intake manifold sender -GX9-
❑ Consisting of
Intake air temperature sender 2 -G299-
Intake manifold pressure sender -G71-

❑ Removing and installing ⇒ a5.1 nd installing intake manifold senderGX9”, page 487
❑ Removing and installing ⇒ a2.4 nd installing electric coolant pump”, page 354
12 - Ignition coils with output stages
♦ Ignition coil 1 with output stage -N70-
❑ Removing and installing ⇒ a1.2 nd installing ignition coils with output stage”, page 580
Overview of fitting locations – engine, intake side

1 - Knock sensor 1 -G61-

❑ Assembly overview ⇒
o1.1 verview - ignition
system”, page 578
2 - Oil pressure switch for re‐
duced oil pressure -F378-
a4.3 nd installing oil
pressure switch for
reduced oil pressur‐
eF378”, page 325
3 - Fuel pressure sender -
G247-
o2.1 verview - fuel rail
with injectors”, page
449
4 - Activated charcoal filter
solenoid valve 1 -N80-
5 - Injectors
♦ Injector, cylinder 1 -N30-
o2.1 verview - fuel rail
with injectors”, page
449
6 - Fuel pressure regulating
valve -N276-
❑ On high-pressure pump
o7.1 verview - high-
pressure pump”, page 519
7 - Engine speed sender -G28-
❑ Assembly overview ⇒ o1.1 verview - ignition system”, page 578
Overview of fitting locations - engine, exhaust side
1. Injection system 447

1 - Charge air pressure con‐

troller -V465-
o1.1 verview - turbo‐
charger”, page 416
charge pressure posi‐
tionerV465”, page 426
o8.1 verview - Lambda
probe”, page 530
Lambda probe”, page
531
3 - Oil pressure switch -F1-
oil pressure switchF1”,
page 324
4 - Valve for oil pressure con‐
trol -N428-
oil pressure regulating
valveN428”, page 328
5 - Oil level and oil tempera‐
ture sender -G266-
oil level and oil tem‐
perature senderG266”,
page 314
6 - Lambda probe 1 after catalytic converter -GX7-
❑ Assembly overview ⇒ o8.1 verview - Lambda probe”, page 530
❑ Removing and installing ⇒ a8.2 nd installing Lambda probe”, page 531
7 - Radiator outlet coolant -G62-
❑ Removing and installing ⇒ a2.8 nd installing coolant temperature senderG62”, page 367

2 Injectors
⇒ o2.1 verview - fuel rail with injectors”, page 449
⇒ a2.2 nd installing fuel rail”, page 453
⇒ a2.3 nd installing injectors”, page 454
⇒ i2.4 njectors”, page 468
2.1 Assembly overview - fuel rail with injec‐

tors
⇒ o2.1.1 verview - fuel rail with injectors, vehicles without partic‐
ulate filter”, page 449
⇒ o2.1.2 verview - fuel rail with injectors, vehicles with particu‐
late filter”, page 451
2.1.1 Assembly overview - fuel rail with injectors, vehicles without particulate
filter
2. Injectors 449

G247-
❑ Checking ⇒ f5.3 uel
pressure senderG247”,
page 489
ling fuel pressure send‐
erG247”, page 487
❑ Moisten taper and
thread with clean en‐
gine oil
❑ 22 Nm
2 - Fuel distributor
fuel rail”, page 453
3 - High-pressure pipe
❑ Does not need to be re‐
newed after removal
❑ Unions must be free of
damage
❑ Do not alter shape.
stalling high-pressure
pipe”, page 527
❑ Lubricate thread of un‐
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
4 - Bolt
❑ 8 Nm +90°
5 - Support ring
❑ Fuel rail exerts force which secures injector in cylinder head via this support ring
❑ Shape may vary depending on whether vehicle is fitted with or without particulate filter
❑ Clipped to -item 8-
6 - O-ring
❑ Lubricate with clean engine oil
7 - Spacer ring
8 - Injector
❑ Removing and installing ⇒ a2.3 nd installing injectors”, page 454
9 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
❑ Renewing ⇒ a2.3 nd installing injectors”, page 454

2.1.2 Assembly overview - fuel rail with injectors, vehicles with particulate filter
2. Injectors 451
1 - Fuel distributor
2 - Bolt
❑ M6 × 30
❑ Qty. 4
❑ 8 Nm +90°
G247-
❑ Checking ⇒ f5.3 uel
pressure senderG247”,
page 489
ling fuel pressure send‐
erG247”, page 487
❑ Moisten taper and
thread with clean en‐
gine oil
❑ 22 Nm +10°
4 - Injector
injectors”, page 454
5 - O-ring
❑ Renew
❑ Coat lightly with clean
engine oil when instal‐
ling.
6 - Spacer ring
❑ Renew
7 - Spacer ring
❑ Renew
8 - Support ring
❑ Renew
❑ Fuel rail exerts force which secures injector in cylinder head via this support ring
❑ Clipped to -item 4-
9 - Taper seal
10 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
❑ Renewing ⇒ a2.3 nd installing injectors”, page 454
❑ Does not need to be renewed after disassembly
❑ Unions must be free of damage
❑ Removing and installing ⇒ a7.3 nd installing high-pressure pipe”, page 527
❑ Lubricate thread of union nuts with clean engine oil
❑ 16 Nm +45°

12 - Bolt
❑ Can be reused
❑ M6 × 14
❑ 8 Nm +90°
13 - Clip
2.2 Removing and installing fuel rail

Removing
Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

fold”, page 481 .
– Remove high-pressure pipe ⇒ a7.3 nd installing high-pres‐
sure pipe”, page 527 .
– Place a cloth underneath to catch escaping fuel.

– Remove bolts -arrows- and pull fuel rail off injectors.
Installing
2. Injectors 453
Note
♦ Renew O-rings.
♦ Before installing, lightly moisten O-rings with clean engine
oil.
♦ Visually inspect fuel rail and remove any foreign bodies or
old O-rings as necessary.
♦ If there is still an O-ring in the fuel rail, carefully lever out the
O-ring using removal wedge -3409-.
♦ The sealing surfaces in the fuel rail must be free of scoring
or scratches. Otherwise the component must be renewed.
– Apply mountings on fuel rail onto injectors.

– Press fuel rail onto injectors as far as stop (first on right side,
then on left side).
– Firmly press down fuel rail in area of bracket and screw in
bolts by two full turns.
– Tighten bolts evenly and diagonally.
pipe”, page 527 .
page 481 .
Specified torques
♦ ⇒ o2.1 verview - fuel rail with injectors”, page 449
2.3 Removing and installing injectors

⇒ a2.3.1 nd installing injectors, vehicles without particulate fil‐
ter”, page 454
⇒ a2.3.2 nd installing injectors, vehicles with particulate filter”,
page 461
2.3.1 Removing and installing injectors, vehi‐

cles without particulate filter
♦ Tool set for FSI engines -T10133 C- with -T10133/16 A- and
-T10133/19-

Removing
Note
Injectors must only be removed when the engine is cold.

fold”, page 481 .
– Removing fuel rail ⇒ a2.2 nd installing fuel rail”, page 453 .
– Remove O-ring -3- from injector -1-.

– Unplug electrical connector from corresponding injector.
– Lever support ring -1- off injector using a screwdriver -2-.
– Fit impact sleeve -T10133/18A- over injector.
2. Injectors 455
– Carefully loosen injector with light blows onto impact sleeve.
Note
♦ Use a torque wrench to pull out the injector.

♦ Set the torque wrench to 5 Nm.
– Fit puller -T10133/19- to groove on injector.

– Fit removing tool -T10133/16 A- to puller.

– Pull out injector by screwing in bolt -1-.
– If the torque limit of »5 Nm« has been reached and it is still
not possible to loosen the injector, withdraw the puller, and
start anew.
– Repeat the procedure on each injector.
Note
♦ If the torque limit is exceeded, the injector may become

damaged.
♦ Always renew the combustion chamber seal prior to reinstal‐
ling the injector.
– Remove gasket for lower part of intake manifold.

Dismantling injectors:
– Pull support ring -4- and spacer ring -2- off injector -1-.
2. Injectors 457
– Remove retaining ring -7-, upper sealing washer -5- and

lower sealing washer -6-.
– Carefully remove old combustion chamber seal -8-.
– To to this, cut seal open with a knife, or use a small screw‐
driver to spread ring, and pull it off towards front.
Note
Take care not to damage the groove of injector. The injector

must be renewed if the groove is damaged.
Installing
– Clean hole in cylinder head using nylon brush -T10133/4-.
Note
♦ Renew combustion chamber seal and O-ring.

♦ Renew spacer ring if damaged.
– When reinstalling the injector, remove any combustion resi‐

due from groove for combustion chamber ring seal and from
injector shaft using a clean cloth.
– Fit assembly cone -T10133/5- with a new combustion cham‐
ber seal -1- on injector -2-.
– Slide combustion chamber seal with assembly sleeve -

T10133/6- onto assembly cone -T10133/5- as far as it will
go.

– Turn assembly sleeve -T10133/6- around and push combus‐

tion chamber ring seal into the respective groove.
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. It must be compressed again after sliding on
and this is done in two stages as described below.
– Push calibration sleeve -T10133/7- onto injector as far as

stop and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again, turning in oppo‐
site direction.
– Push calibration sleeve -T10133/8- onto injector as far as
stop and simultaneously turn it slightly (approx. 180°).
2. Injectors 459

site direction.
– Fit support ring -4- and spacer ring -2- onto injector -1-.
– Before installing injector -1- moisten new O-ring -3- with
clean engine oil.
Note
The combustion chamber seal -8- must not be lubricated.
– Push injectors by hand as far as they will go into the hole of

the cylinder head (must be free of oil and grease). Ensure
injectors are positioned correctly in cylinder head.
Note
♦ The injectors must insert easily. If necessary, wait until the

combustion chamber ring seal has contracted sufficiently.
♦ Ensure injectors are correctly seated and positioned in cylin‐
der head.
• Electrical connector of injector must engage in respective

– Installing fuel rail ⇒ a2.2 nd installing fuel rail”, page 453 .


page 481 .
♦ 0001 - Clear adaption values for injectors
2.3.2 Removing and installing injectors, vehi‐

cles with particulate filter
♦ Removal tool -T10498-
♦ Removal tool -T10133/16A- from tool set for FSI engines

-T10133 C-
♦ Set of tools for high-pressure injector -T10581-
Set of tools for high-pressure injector -T10581-:
2. Injectors 461
A - Press tool -T10581/3-

B - Puller -T10581/4-
C - Removal tool -
T10133/16A-
D - Bolt from removal tool -
T10133/16A-
E - Base plate -T10581/1-
F - Knurled screw -T10581/2-
G - Assembly cone -
T10581/5-
H - Assembly sleeve -
T10581/6-
I - Calibration sleeve -
T10581/7-
J - Cylinder pin for protecting
assembly cone -T10581/5-
Procedure
Note
♦ Injectors must only be removed when the engine is cold.

♦ When pulling off the fuel rail, injectors may be released from
the cylinder head or the fuel rail.
♦ Due to the fuel pressure, all seals on the injector must be
renewed after the removal.
♦ In this case, the injectors must be pulled out of the fuel rail.

fold”, page 481 .
– Removing fuel rail ⇒ a2.2 nd installing fuel rail”, page 453 .

Removing injectors on cylinder head:
– Release and pull off electrical connector -3- on injector -1-.

– Carefully remove seal and spacer rings -2- using removal
tool -T10498-.
– The two spacer rings have slots.
– Slide thrust piece -T10581/3- -A- over injector -1-.
– The thrust piece -T10581/3- -A- must not contact support

ring -2-.
– Carefully loosen injector with light blows onto thrust piece.
– Fit base plate -T10581/1- -E- with knurled screw -T10581/2-
-F-, as shown in illustration.
– Use holes for fuel rail to bolt base plate to cylinder head.
– Fit puller -T10581/4- -B- to groove on injector -1-.
2. Injectors 463
– Insert mounting of puller -T10581/4- in groove of support

rings.
– Unscrew bolt -D- from removal tool -T10133/16A- -C- a few
turns.
– Slide removal tool -T10133/16A- -C- over puller -T10581/4-
-B-.
– Screw bolt -D- of removal tool -T10133/16A- into puller -
T10581/4- -B-.
– Align removal tool -T10133/16A-, and fit it onto base plate
-T10581/1- -E-.
– Turn removal tool -T10133/16A- -C- in such a way that the
contact surface with base plate -T10581/1- -E- is as large as
possible.
– Tighten bolt -D- slightly by hand. Removal tool -T10133/16A-
must be supported on base plate -T10581/1-.
– Use a torque wrench to pull out the injector.
– Set the torque wrench to 5 Nm.
– Pull out injector by screwing in bolt -D-.
– If the torque limit of »5 Nm« has been reached and the injec‐
tor still can't be pulled out, remove the puller. Use the impact
sleeve again to loosen the injector.
– Repeat the procedure on each injector.
Note
If the torque limit is exceeded, the injector may become dam‐

aged.

Dismantling injectors:
1- Injector
2- Seal
3- Spacer ring (white)
4- Spacer ring (red)
5- Combustion chamber seal
6- Support ring
Renewing spacer rings and seals:
– Renew seal -2- and spacer rings -3- and -4- after removal.
– Carefully remove seal -2- using removal tool -T10498-.
– Carefully remove spacer rings -3- and -4- using removal tool
-T10498-. The spacer rings have slots.
– Clean injector shaft using a clean cloth to remove any de‐
posits from combustion.
– Install seal and spacer rings in the specified sequence.
– Before installing injector moisten new seal -2- with clean
engine oil.
Renewing support ring:
– Use a suitable screwdriver to carefully pull old support ring

off injector.
2. Injectors 465
– Fit new support ring to groove -arrow-, and slide it on.

– The opening of the support ring must face toward electrical
connection.
Renewing combustion chamber seal:
– Carefully remove combustion chamber seal using removal
tool -T10498-.
– Take care not to damage the groove of injector. The injector
must be renewed if the groove is damaged.
– When re-installing an injector, clean groove for combustion
chamber seal using a clean cloth to remove any deposits
from combustion.
– Slide assembly cone -T10581/5- -G- to stop onto injector -1-.
– Slide combustion chamber seal -5- to assembly cone -

T10581/5-, as shown in illustration.
– Slide assembly sleeve -T10581/6- -H- onto assembly cone
-T10581/5- -G- until it contacts combustion chamber seal
-5-.
– Use assembly sleeve -T10581/6- to slide combustion cham‐

ber seal as far as possible onto assembly cone -T10581/5-.
– Use assembly sleeve -T10581/6- to slide on combustion
chamber seal until it is seated in the first groove of the seal
⇒ page 465 .
– Pull assembly sleeve -T10581/6- off injector -1-.
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. It must be compressed again after sliding on.
This is done in two stages as described below.

– Push calibration sleeve -T10581/7- -I- to stop onto injector

-1-, and at the same time turn it slightly (approx. 180°)
-arrow-.

site direction.
– Push calibration sleeve -T10581/7- to stop onto injector, and
simultaneously turn it slightly (approx. 180°).
site direction.
Installing
– Clean hole in cylinder head using nylon brush -T10133/4-.
Note
♦ The combustion chamber seal must not be lubricated.

♦ Renew combustion chamber seal, spacer ring and seal.
♦ The injectors must insert easily. If necessary, wait until the
combustion chamber ring seal has contracted sufficiently.
– Push injectors -1- by hand to stop into the hole of cylinder

head (must be free of oil and grease). Ensure injectors are
positioned correctly in cylinder head.
2. Injectors 467
– Electrical connector of injector must engage in respective

– Moisten new seals with clean engine oil.
– Installing fuel rail ⇒ a2.2 nd installing fuel rail”, page 453 .
page 481 .
If injectors have been cleaned:
– Connect ⇒ Vehicle diagnostic tester.
– Carry out function 0001 - Reset learnt injector val-
ues .
If injectors have been renewed:
– Carry out function 0001 - Reset learnt injector val-
ues .
2.4 Cleaning injectors

♦ Ultrasonic cleaning device -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic Parts Catalogue
Note
The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
Observe ultrasonic unit safety regulations and operating instruc‐

tions.

Cleaning
– Remove injectors ⇒ a2.3 nd installing injectors”, page 454 .

– Insert injectors -1- all the way into mounting plate for injec‐
tion modules -VAS 6418/1- -item 2-.
– Immerse injectors together with mounting plate for injection
modules -VAS 6418/1- into cleaning fluid -VAS 6418/2-.
– Set rotary knob -4- to a temperature of 50°C.
– Set a cleaning time of 30 minutes with the rotating knob -5-.
– Switch on ultrasonic unit with button -3-.
Note
The time set starts to elapse as soon as a cleaning temperature

of 50°C has been attained.
– After cleaning, renew combustion chamber ring seal for each

injector ⇒ a2.3 nd installing injectors”, page 454 .
2. Injectors 469
3 Air filter
⇒ o3.1 verview - air filter housing”, page 470
⇒ a3.2 nd installing air filter housing”, page 472
⇒ a3.4 nd installing resonator for intake air”, page 476
3.1 Assembly overview - air filter housing

⇒ o3.1.1 verview - air filter housing, Sharan 2016 >, Tiguan
2008 >, CC 2012 >, T-Roc 2018 >, Golf 2020 >, Golf Estate
2021 >”, page 470
⇒ o3.1.2 verview - air filter housing, Golf Cabriolet and Sciroc‐
co”, page 471
3.1.1 Assembly overview - air filter housing, Sharan 2016 >, Tiguan 2008 >, CC
2012 >, T-Roc 2018 >, Golf 2020 >, Golf Estate 2021 >

1 - Air filter lower part

❑ Remove dirt, leaves
and salt residues
2 - Air duct
❑ On lock carrier
ling (T-Roc) ⇒ a3.3 nd
installing air guide on
lock carrier”, page 474
3 - Bolt
❑ 2 Nm
4 - Cover
❑ For air duct
5 - Bolt
❑ 1.5 Nm
6 - Air intake hose
7 - Clip
8 - Hose
tion.
9 - Air filter upper part
and salt residues
10 - Air duct (bottom section)
❑ On lock carrier
11 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance tables
❑ Removing and installing ⇒ Maintenance; Booklet
12 - Air intake hose
13 - Bolt
❑ 2 Nm
14 - Rubber buffer
15 - Water drain hose
❑ Cleaning
3.1.2 Assembly overview - air filter housing, Golf Cabriolet and Scirocco
3. Air filter 471

1 - Rubber buffer
2 - Water drain hose
❑ Cleaning
3 - Bolt
❑ 1.5 Nm
4 - Air filter lower part
and salt residues
5 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance
tables
ling ⇒ Maintenance;
Booklet
6 - Air filter upper part
and salt residues
7 - Hose
tion.
8 - Air intake hose
9 - Clip
10 - Air intake hose
11 - Cover
❑ For air duct
12 - Air duct (bottom section)
❑ On lock carrier
13 - Bolt
❑ 2 Nm
14 - Air duct
❑ On lock carrier
3.2 Removing and installing air filter hous‐

ing
Removing
– Pull vacuum hose -2- off air filter housing -1-.

– Release spring-type clips -3- and -4-, and remove intake

hoses.
– Lift air filter housing -1- off ball studs in the following se‐
quence.
– First pull air filter housing off ball stud -C-.
– Then, and only then, pull air filter housing off ball studs -B-
and -A-.
Installing
3. Air filter 473

Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the components and falsify the measured
air mass value. This would lead to loss of power, since a
smaller injection quantity is calculated.
♦ Always use Genuine part for air filter element.
♦ A clean air filter housing is essential.
♦ Before fitting the air filter housing, the ball pins on the intake
manifold must be moistened with water without additives.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Use a silicone-free lubricant to install the air hoses.
♦ Secure all hose connections with the hose clips correspond‐
ing to original equipment ⇒ Electronic Parts Catalogue.
♦ Avoid malfunctions. When blowing out air filter housing with
compressed air, cover critical components through which air
flows.
♦ Use a clean cloth to do this.
♦ Observe relevant disposal regulations.
– Remove salt residues, dirt and leaves from top and bottom
part of air filter housing using a vacuum cleaner.
– Blow out water drain with compressed air.
• Keep to the sequence during assembly.
– Press air filter housing -1- on ball studs -A- and -B-.
– Finally, press air filter housing on ball stud -C-.

Specified torques
3.3 Removing and installing air guide on

lock carrier

Removing
– Remove radiator grille ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Assembly overview - bumper
cover.
– Unscrew bolts -3- from cover -1-.
– Release rear fastener -2- -arrow-.

– Release front fastener -arrow- and remove cover -1-.
– Loosen hose clip -2-, and pull air intake hose off bottom
section of air duct -1-.
3. Air filter 475

– Release fastener -arrow-, and detach bottom section of air

duct -1-.
– Unscrew bolts -arrows-, and remove air duct -1-.
Installing
Note
Reinstall hose clips in their original positions.
Specified torques
♦ ⇒ o3.1.1 verview - air filter housing, Sharan 2016 >, Tiguan
2008 >, CC 2012 >, T-Roc 2018 >, Golf 2020 >, Golf Estate
2021 >”, page 470
3.4 Removing and installing resonator for

intake air
Removing
– Loosen hose clips -1- and -2-.

– Remove resonator for intake air.

Installing
Note
Reinstall hose clips in their original positions.
3. Air filter 477

4 Intake manifold
⇒ o4.1 verview - intake manifold”, page 478
⇒ a4.2 nd installing intake manifold”, page 481
⇒ a4.3 nd installing throttle valve moduleGX3”, page 484
⇒ t4.4 hrottle valve moduleGX3”, page 485
4.1 Assembly overview - intake manifold

1 - Coolant pipe
manifold.
ling coolant pipe ⇒
a3.2 nd installing cool‐
ant pipes”, page 374
2 - Intake manifold
❑ Combined with charge
air cooler
intake manifold”, page
481
3 - Coolant pipe
manifold.
4 - Bolt
page 480
5 - O-ring
6 - Intake manifold sender -
GX9-
❑ Consisting of
Intake air temperature
sender 2 -G299-
Intake manifold pressure

sender -G71-
intake manifold senderGX9”, page 487
7 - Seals
8 - Charge air pressure sender -GX26-
❑ Consisting of
Charge pressure sender -G31-
Intake air temperature sender -G42-

❑ Removing and installing ⇒ a2.3 nd installing charge pressure senderGX26”, page 438
9 - O-ring
10 - Union
11 - O-ring
12 - Air intake pipe
❑ For removal, use release tools -T10527- and -T10527/1-
13 - O-ring
4. Intake manifold 479

14 - Bolt
❑ Thread-cutting
torque.
❑ 7 Nm
15 - Retaining clip
❑ For air intake pipe
❑ Consisting of
❑ Cleaning ⇒ t4.4 hrottle valve moduleGX3”, page 485
❑ After throttle valve control module -GX3- has been replaced, it must be re-adapted to engine control
unit -J623-. Use vehicle diagnostic tester for this.
17 - Seal
18 - Vacuum line
19 - O-ring
❑ In event of damage to O-ring, renew vacuum line ⇒ Item 18 (page 480)
20 - Vacuum line
21 - O-ring
❑ In event of damage to O-ring, renew vacuum line ⇒ Item 20 (page 480)
Intake manifold - specified torque and tightening sequence
– Tighten bolts -arrows- in stages as follows:

1st -Arrows- Starting in centre, screw in bolts alter‐
nately by hand until they make contact
2nd -Arrows- Starting in centre, screw in bolts alter‐
nately to 8 Nm

4.2 Removing and installing intake mani‐

fold
Removing
ing”, page 472 .
insulation.
– Release and separate plug-in connector -2-. Disconnect
plug-in connectors ⇒ Rep. gr. 20; Plug-in connectors; Dis‐
connecting plug-in connectors.



441 .
– Unscrew bolt -1-, and release clamps -arrows-.
– Pull off coolant hoses.


1 - For activated charcoal filter system solenoid valve 1 -N80-

3 - For throttle valve module -GX3-
4 - For intake manifold sender -GX9-.
– The -arrow- in the illustration can be disregarded.
– Press release buttons and pull off hose -2- for activated
charcoal filter.
– Unclip fuel supply line -5- and coolant line -6- from intake
manifold and push them to one side.
– Disconnect connector -1- from fuel pressure sender -G247-.
– Also disconnect connector from oil pressure switch.

– Loosen hose clips -2- and pull off coolant hoses.

– Remove intake manifold -1-.
Installing

Note
Renew seals and O-rings.

insulation.
page 472 .
Specified torques
4.3 Removing and installing throttle valve

module -GX3-
Throttle valve module -GX3- consists of
♦ Throttle valve module -J338-
♦ Throttle valve drive for electronic power control -G186-
♦ Throttle valve drive angle sender 1 for electronic power con‐
trol -G187-
♦ Throttle valve drive angle sender 2 for electronic power con‐
trol -G188-
Removing
441 .
– Unscrew bolts -arrows- and remove throttle valve module

-GX3- -1- with adapter -2-.
Installing
• After throttle valve control module -GX3- has been replaced,
it must be re-adapted to engine control unit -J623-.
♦ 0001 - Adaption throttle valve module J338
Specified torques

4.4 Cleaning throttle valve module -GX3-
Note
♦ If a new engine control unit -J623- is installed the throttle

valve module must be adjusted.
♦ Contamination and coking in end stop can result in incorrect
adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

♦ Acetone (commercially available)
♦ Brush
– Remove throttle valve module -GX3- ⇒ a4.3 nd installing
throttle valve moduleGX3”, page 484 .
– Open throttle valve by hand and lock it in open position with
a wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
– Clean throttle valve housing thoroughly, especially around

the points -arrows- where the throttle valve closes, using
commercially available acetone and a small brush.

– Wipe the inside of the throttle valve housing with a lint-free

cloth.
– Allow acetone to dry off completely.
– Install throttle valve module -GX3- ⇒ a4.3 nd installing throt‐
tle valve moduleGX3”, page 484 .
– Delete learnt values and adapt engine control unit -J623- to
throttle valve module -J338-.
♦ 0001 - Clear adaption values for injectors

5 Senders and sensors

⇒ a5.1 nd installing intake manifold senderGX9”, page 487
⇒ a5.2 nd installing fuel pressure senderG247”, page 487
⇒ f5.3 uel pressure senderG247”, page 489
⇒ a5.4 nd installing exhaust gas pressure sensor 1G450”, page
493
5.1 Removing and installing intake mani‐

fold sender -GX9-
Intake manifold sender -GX9- consists of:
♦ Intake air temperature sender 2 -G299-
♦ Intake manifold pressure sender -G71-
Removing
ing”, page 472 .
– Release fasteners, and remove intake manifold sender -

GX9-.
Installing
Note
♦ Renew O-ring.
♦ If the retaining tabs broke off during removal, the sender
can be mounted using two securing bolts ⇒ Electronic parts
catalogue.

page 472 .
Specified torques
Intake manifold sender -GX9- 3 Nm
5.2 Removing and installing fuel pressure

sender -G247-
5. Senders and sensors 487

♦ Socket 27 mm -T40218- or commercially available 27 mm

hexagon socket insert
Removing
ing”, page 472 .
– Unclip fuel supply line -1- from intake manifold, and push it
to one side.
CAUTION
– Unscrew fuel pressure sender -G247- -3- using socket 27

mm -T40218-.

Installing
– Lubricate cone and thread of fuel pressure sender with clean
engine oil.
Specified torques
5.3 Checking fuel pressure sender -G247-

⇒ f5.3.1 uel pressure senderG247, using pressure sensor test‐
erVAS 6394 and vehicle diagnostic tester”, page 489
⇒ f5.3.2 uel pressure senderG247, using vehicle diagnostic
tester”, page 491
5.3.1 Checking fuel pressure sender -G247-,

using pressure sensor tester -VAS
6394- and vehicle diagnostic tester
♦ ⇒ Vehicle diagnostic tester
♦ Pressure sensor tester -VAS 6394-
♦ Test instrument adapter/DSO (3-pin) -VAS 5570-

♦ Socket 27 mm long, commercially available
CAUTION
– Release high pressure.
– Remove fuel pressure sender - G247- ⇒ a5.2 nd installing

fuel pressure senderG247”, page 487 .
– Lubricate taper seal of adapter -VAS 6394/3- with clean en‐
gine oil and screw into fuel rail (22 Nm).

– Unscrew plug -2- and screw fuel pressure sender - G247-

into tester -VAS 6394/1-.
– Connect pressure line -1- of tester to adapter -VAS 6394/3-.

– Connect vehicle and fuel pressure sender - G247- electrical‐
ly using test instrument adapter/DSO (3-pin) -VAS 5570-.
– Switch on tester -VAS 6394/1- by pressing button -A- once

briefly.

Note
♦ When button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If tester -VAS 6394/1- does not indicate 0 bar, zero the
tester ⇒ Operating instructions.
– Connect a ⇒ Vehicle diagnostic tester.

– Start engine and run it at idling speed.
– Select 0001 - Read measured values in self-diagnosis.
– Select Fuel pressure from the list.
– Compare pressure from tester -VAS 6394/1- with actual val‐
ue displayed on ⇒ Vehicle diagnostic tester.
– Watch the fuel pressure on the vehicle diagnostic tester.
• A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, renew fuel pressure
sender - G247-.
– Repeat test with new fuel pressure sender - G247- and com‐
pare both measured values.
– If measured values are now the same, install new fuel pres‐
sure sender - G247-.
– If measured values are not the same again, check electrical
connection between fuel pressure sender - G247- and en‐
gine control unit -J623- ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
Specified torques
5.3.2 Checking fuel pressure sender -G247-,

using vehicle diagnostic tester
♦ Pressure gauge -VAS 6550-

Condition:
• 1/
4 of fuel tank filled with fuel.
– Pull off supply line -1-. Separate plug-in connectors ⇒ Fuel
supply system - petrol engines; Rep. gr. 20; Plug-in connec‐
tors; Separating plug-in connectors.

CAUTION
– Collect escaping fuel with a cleaning cloth.

– Connect hose -VAS 6550/1- to connection -A- of pressure
tester -VAS 6550-.
– Connect hose -VAS 6550/1- to fuel supply line -1- leading to

engine.
– Connect hose -VAS 6550/2- to connection -B- of pressure
tester -VAS 6550-.
– Use hose -VAS 6550- to connect fuel line leading to fuel
tank with pressure tester -VAS 6550/2-.
– Ensure plug-in connectors are secure properly by pulling.
– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Use ⇒ Vehicle diagnostic tester to check fuel pressure send‐
er -G247-. To do this, select following function:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics
♦ 0001 - Repair groups
♦ 24 - Mixture preparation/injection
♦ G247 - Check fuel pressure sender
5.4 Removing and installing exhaust gas

pressure sensor 1 -G450-
♦ Socket 24 mm -T40284-

♦ Ratchet wrench -V.A.G 1331/1-
Removing
– Release and pull off connector -2-.
– Use socket, 24 mm -T40284- to unscrew exhaust gas pres‐
sure sensor 1 -G450- -arrow-.
Installing
Note
♦ Renew exhaust gas pressure sensor 1 -G450- after removal.

♦ Before installing the exhaust gas pressure sensor 1 -G450-,
check hole in camshaft housing for soiling.
– Tighten exhaust gas pressure sensor 1 -G450- to specified

torque.
Specified torques:
♦ 25 Nm

6 Engine control unit

⇒ a6.2 nd installing engine control unitJ623”, page 496
⇒ a6.3 nd installing engine (motor) control unitJ623 with protec‐
tive housing”, page 502
6.1 Assembly overview - engine control

unit -J623-
⇒ o6.1.1 verview - engine control unitJ623, Golf 2020 >, Golf
6.1.1 Assembly overview - engine control unit -J623-, Golf 2020 >, Golf Estate
2021 >
1 - Bracket
2 - Nuts
❑ Qty. 2
❑ 8 Nm
3 - Protective housing
4 - Shear bolts
❑ Qty. 3
5 - Engine control unit -J623-
stalling engine control
unitJ623”, page 496
6. Engine control unit 495

6.2 Removing and installing engine control

unit -J623-
⇒ a6.2.1 nd installing engine control unitJ623, Sharan and Ti‐
guan”, page 496
⇒ a6.2.2 nd installing engine control unitJ623, Golf Cabriolet,
Scirocco and CC”, page 498
⇒ a6.2.3 nd installing engine control unitJ623, Golf 2020 >, Golf
6.2.1 Removing and installing engine control

unit -J623-, Sharan and Tiguan
Note
Removing and installing anti-theft engine control unit ⇒

a6.3.1 nd installing engine control unitJ623 with protective
housing, Sharan and Tiguan”, page 502 .
Removing
– If the engine control unit is to be renewed, switch on ignition,
and select the following menu option on⇒ Vehicle diagnostic
tester:
♦ 0001 - Renew engine control unit
– Switch off ignition and remove key from ignition lock.
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper arms.
head.
– If fitted, pull connector off heated windscreen control unit
-J505-.
– Pull seal together with engine wiring harness upwards in
-direction of arrow- out of cable guide.
– If fitted, unclip cover -1- at sides from mountings -2-


– Remove nut -3-.
– Raise engine control unit -1- in front area in

– Pull engine control unit forwards out of the side guides -2-.
– Slide connector locking devices -1- on engine control unit in
-direction of arrow- and pull off both connectors.

Installing
– Attach connectors to engine control unit and slide locking
devices inwards until they engage.
– Push engine control unit -1- into side guides -2- in the

exterior; Rep. gr. 50; Plenum chamber bulkhead.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50; Plenum chamber cover.
– Wiper arms ⇒ Electrical system; Rep. gr. 92; Windscreen
wiper system; Removing and installing wiper arms.
Specified torque for securing nuts of retaining frame
Nuts Specified torque

Nuts -3- for bracket of engine 6 Nm
control unit

unit -J623-, Golf Cabriolet, Scirocco
and CC
Removing
and select the following menu option on⇒ Vehicle diagnostic
tester:


exterior; Rep. gr. 50; Bulkhead; Assembly overview - plenum
chamber cover.
Golf Cabriolet
– Detach wiring harness for engine control unit from inner side
of plenum chamber bulkhead.
exterior; Rep. gr. 50; Plenum chamber; Assembly overview -
plenum chamber cover.
– Release feed-through for wiring harness -arrow-, and pull it
off upwards.
– Detach wiring harness for engine control unit.
– Release and pull off connector on wiper motor ⇒ Electrical
system; Rep. gr. 92; Windscreen wiper system; Removing
and installing windscreen wiper system.
– Pull engine control unit as far as possible towards front right
wheel housing.
– Detach engine control unit from plenum chamber.
– Push down retaining frame in direction of -arrow- and re‐

move engine control unit.
– Push locking devices of connectors in -direction of arrow-
and pull off connectors.

Installing
– Fit connectors to engine control unit and slide locking devi‐

ces onto stop in -direction of arrow-.
– Insert engine control unit into retaining frame and push re‐
taining frame upwards in direction of -arrow-.
Specified torques
♦ ⇒ Electrical system; Rep. gr. 92; Removing and installing
wiper arms
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Plenum cham‐
ber cover
♦ ⇒ Electrical system; Rep. gr. 92; Windscreen wiper system;
Removing and installing windscreen wiper system
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Plenum cham‐
ber bulkhead


unit -J623-, Golf 2020 >, Golf Estate
2021 >
Removing
– When renewing engine control unit, connect ⇒ Vehicle diag‐
nostic tester.
– Select 0001 - Renew engine control unit function.
Note
If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine (mo‐
tor) control unit will be the consequence.

Disconnecting and connecting battery.
– Release catch -arrow A-, and remove engine control unit
-J623- -arrow B-.
– Release and pull off connectors for engine (motor) control

unit -J623-.

Installing

– Insert lower edge of engine control unit -J623- into bracket
-arrow A-, and engage engine control unit in bracket at up‐
per edge.
• When doing this, ensure that lugs of engine control unit en‐
gage in notches at top and bottom of bracket -arrows B-.
– Connect battery ⇒ Electrical system; Rep. gr. 27; Battery;
6.3 Removing and installing engine (mo‐

tor) control unit -J623- with protective
housing
⇒ a6.3.1 nd installing engine control unitJ623 with protective
housing, Sharan and Tiguan”, page 502
housing, Golf Cabriolet, Scirocco and CC”, page 506
housing, T-Roc”, page 512
housing, Golf 2020 >, Golf Estate 2021 >”, page 515
6.3.1 Removing and installing engine con‐

trol unit -J623- with protective housing,
Sharan and Tiguan

♦ Hot air blower -VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set -VAS 1978 B-
♦ Vehicle diagnostic tester
Note
♦ If the engine control unit is to be replaced, connect the

vehicle diagnostic tester and carry out the guided function
“Renewing engine control unit”.
♦ The shear-head bolt threads may coated with locking com‐
pound. To simplify removal, the shear-head bolts can be
heated using hot air blower -VAS 1978/14A-. When doing
this, make sure not to damage adjacent cables, connectors
or other components.
Note
Removing and installing anti-theft engine control unit ⇒

a6.3.1 nd installing engine control unitJ623 with protective
housing, Sharan and Tiguan”, page 502 .
Removing
and select the following menu options on vehicle diagnostic
tester:
head.
– If fitted, pull connector off heated windscreen control unit
-J505-.
– Pull seal together with engine wiring harness upwards in
-direction of arrow- out of cable guide.

– If fitted, unclip cover -1- at sides from mountings -2-

– If fitted, unscrew nut -arrow- from alarm horn -H12-.
The alarm horn -H12- remains in its installation position.

– Unscrew nuts -3-, and remove engine control unit -J623- -1-
upwards.
– Unclip retainer -4- from pins, and remove wiring harness
with engine control unit -J623- connected as far as possible.
– Bend upwardly projecting tabs -1- of locking bar outwards.

– Loosen shear bolts -2- using mole grips.

– Unscrew shear bolts -arrow-, and remove locking bracket
-1-.
– Open connector locks on engine control unit, and pull off

connectors -2 and 3-.
Installing
– Attach connectors to engine control unit and slide locking
devices inwards until they engage.
– Screw on a new locking bar -3- with new shear-head bolts
-2- and tighten bolts uniformly until just before heads shear
off.
Disregard item -1-.

– Push engine control unit -1- into side guides -2- in the


head.
– Install plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50; Plenum chamber bulkhead; Assembly
overview - plenum chamber cover.
– Wiper arms ⇒ Electrical system; Rep. gr. 92; Windscreen
wiper system; Removing and installing wiper arms.
Specified torque for securing nuts of retaining frame
Nuts Specified torque

Nut -arrow- for alarm horn - 20 Nm
H12-
Nuts -3- for bracket of engine 6 Nm
control unit

Golf Cabriolet, Scirocco and CC

♦ Small grinder (commercially available)

♦ Vehicle diagnostic tester
Note
♦ If the engine control unit is to be replaced, connect the

vehicle diagnostic tester and carry out the guided function
“Renewing engine control unit”.
♦ The shear-head bolt threads may coated with locking com‐
pound. To simplify removal, the shear-head bolts can be
heated using hot air blower -VAS 1978/14-. When doing this,
make sure not to damage adjacent cables, connectors or
other components.
Removing
and select the following menu options on vehicle diagnostic
tester:
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92; Re‐
moving and installing wiper arms.
– Removing plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Plenum chamber cover.
Golf Cabriolet
– Detach wiring harness for engine control unit from inner side
of plenum chamber bulkhead.
exterior; Rep. gr. 50; Plenum chamber bulkhead.
– Release feed-through for wiring harness -arrow-, and pull it
off upwards.

– Detach wiring harness for engine control unit.

– Release and pull off connector on wiper motor ⇒ Electrical
system; Rep. gr. 92; Windscreen wiper system; Removing
and installing windscreen wiper system.
– Pull engine control unit as far as possible towards front right
wheel housing.
– Detach engine control unit from plenum chamber.
– Push down retaining frame in direction of -arrow- and re‐

move engine control unit.
– Make groove (for a screwdriver) in head of shear bolt -1-
using a small grinder -2-.

Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
Set hot air blower as shown in illustration.

• Turn potentiometer for temperature adjustment -2- to maxi‐
mum heater output
• Two-stage switch for air flow rate -3- set to position 3.
NOTICE
Risk of damage to adjacent components caused by hot air
blower. Risk of overheating.
– If necessary, cover adjacent components.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.
– Unscrew shear bolt -1- with screwdriver -2-.

– Remove protective housing from engine (motor) control unit

-J623-.
– Unscrew shear-head bolts -arrows- using a pair of pliers.
– Insert screwdriver between both locking plates -arrow-.
– Carefully press screwdriver in direction of -arrow- while si‐

multaneously bending locking bar -1- upwards.
– Bend locking bar -1- in -direction of arrow- until it can be
pulled off connector.
– Push locking devices of connectors in -direction of arrow-

and pull off connectors.

Installing
– Fit connectors to engine control unit and slide locking devi‐
ces onto stop in -direction of arrow-.
– Fit retaining bar -1- onto connectors and press it in direction

of -arrow-.
– Guide pin -2- to stop into hole on engine control unit.

– Use new shear-head bolts -arrows- to secure locking bar on
engine control unit.

– Evenly tighten shear-head bolts until bolt heads shear off

-arrows-.
– Insert engine control unit into retaining frame and push re‐
taining frame upwards in direction of -arrow-.
Golf Cabriolet
– Install plenum chamber bulkhead, plenum chamber cover
and wiper arms ⇒ General body repairs, exterior; Rep.
gr. 50; Plenum chamber bulkhead.
CC
– Install wiper arms and plenum chamber cover ⇒ General
body repairs, exterior; Rep. gr. 50; Bulkhead; Removing and
installing plenum chamber cover.

unit -J623- with protective housing, T-
Roc


Removing
– If engine control unit is replaced, switch on ignition and con‐
nect ⇒ Vehicle diagnostic tester.
– Select function 0001 - Renew engine control unit .
Note
If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine (mo‐
tor) control unit will be the consequence.

To remove protective housing -1-, unscrew shear bolts -arrows-
as follows:
Note
Cover the area around the engine control unit, and protect it
from flying sparks.


Note
the hot air blower.
– Set hot air blower as shown in illustration. Set potentiometer

for temperature regulation -2- to maximum heating output
and 2-stage switch for air volume -3- to position 3.
NOTICE
– Apply heat to head of shear bolt -1- for approx. 20 to 30 sec‐

onds.
– Release catch -arrow-, and remove engine control unit -1-.


unit -J623-.
Installing
• It is essential that the engine (motor) control unit -J623- be
provided with the protective housing again.
– Clean threaded holes for shear-head bolts from locking fluid
residue. A thread chaser is suitable for cleaning.
– Use new shear-head bolts.

Golf 2020 >, Golf Estate 2021 >
♦ Wiring harness repair set -VAS 1978 B-
♦ Hot air blower -VAS 1978/14A-


Removing
– If engine control unit is renewed, select 0001 - Renew en-
gine control unit function in ⇒ Vehicle diagnostic tester.
– Store the vehicle key and other entry and start authorisation
systems outside the vehicle to prevent the vehicle from be‐
ing switched on unintentionally.
Note
♦ If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence.
♦ Therefore, make sure to disconnect the battery before re‐
moving the engine control unit.

To remove protective housing -1-, unscrew shear bolts -arrows-
as follows:
Note
Cover the area around the engine control unit, and protect it
from flying sparks.


Note
the hot air blower.
– Set the hot air blower as shown in illustration. Meaning po‐

tentiometer for temperature regulation -2- set to maximum
heating power and 2-stage switch for air volume -3- set to
position 3.
NOTICE
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.
– Release fastener -arrow- and detach engine control unit -1-.


unit -J623-.
Installing
– It is essential that the engine (motor) control unit -J623- be
provided with the protective housing again.
– Clean the threaded holes for the shear-head bolts of locking
compound residues. A thread chaser is suitable for cleaning.
– Use new shear-head bolts.
After installing a new engine control unit, the following opera‐
tions must be performed:
– Restore operational readiness then select and execute the
following menu option on ⇒ Vehicle diagnostic tester:

7 High-pressure pump
⇒ o7.1 verview - high-pressure pump”, page 519
⇒ a7.2 nd installing high-pressure pump”, page 525
⇒ a7.3 nd installing high-pressure pipe”, page 527
7.1 Assembly overview - high-pressure

pump
⇒ o7.1.1 verview - high-pressure pump, version 1”, page 519
7.1.1 Assembly overview - high-pressure pump, version 1
7. High-pressure pump 519

1 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
2 - O-ring
❑ Renew
ling.
3 - High-pressure pump
❑ With fuel pressure reg‐
ulating valve -N276-.
❑ Do not dismantle.
high-pressure pump”,
page 525
newed after removal
damage
pipe”, page 527
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M8x32
❑ Renew
6 - Hose clamp
7 - Fuel supply line
High-pressure pump - specified torque and tightening sequence

Note
♦ High-pressure pumps from different manufacturers have

been installed.
♦ Bear in mind the different torque specifications for bolts!
To prevent flange of high-pressure pump from being deformed

during installation, install high-pressure pump as follows:
– Tighten new bolt in stages as follows:
Stage M8 bolts Specified torque/turning further angle
1st -3- Screw onto stop by hand
2nd -3- Tighten one turn alternately until
flange of high-pressure pump makes
contact with camshaft housing
3rd -3- 20 Nm
4th -3- Turn 90° further

1 - Roller tappet
engine oil
2 - O-ring
❑ Renew
engine oil
page 525
newed after removal
pipe”, page 527
damage
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M8x25
❑ Renew
6 - Hose clamp

Note

been installed.

3rd -3- 20 Nm

1 - Roller tappet
engine oil
2 - O-ring
❑ Renew
ling.
page 525
newed after removal
damage
pipe”, page 527
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M6×22 (1st version)
❑ M6×26 (2nd version)
❑ Renew
6 - Clip
7 - Hose clamp
9 - Serrated washer
❑ Fit directly behind spring-type clip
❑ As shown in illustration, cap points in direction of fuel pressure regulating valve -N276-

Note

been installed.

3rd -3- 8 Nm
7.2 Removing and installing high-pressure

pump

♦ Ratchet attachment -V.A.G 1410/3-
♦ Bit XZN 10 -T10385-
Removing
• Engine cold.

– Release hose clip -2- and detach fuel supply hose.
– Unscrew bolts -3- and detach high-pressure pump with roller
tappet.
Installing
– Check roller tappet for damage and renew if necessary.
– Moisten roller tappet -1- with clean engine oil.
– Insert oiled roller tappet -1- into camshaft housing.

Note
Renew O-ring.
– Turn crankshaft in direction of engine rotation until roller

tappet is at bottom dead centre.
– Insert new, lubricated O-ring -2- in groove of high-pressure
pump -3-.
– Tighten bolts by hand.
– Tighten bolts in diagonal sequence to specified torque ⇒
Fig. ““High-pressure pump - specified torque and tightening
sequence”“, page 520 .
pipe”, page 527 .
– Check fuel system for leaks.
– Note that there are different types of high-pressure pump ⇒
o7.1 verview - high-pressure pump”, page 519 .
Specified torques
♦ ⇒ o7.1.1 verview - high-pressure pump, version 1”, page 519
7.3 Removing and installing high-pressure

pipe

♦ Ratchet attachment -V.A.G 1410/3-
♦ Tool set -T10395B-
Removing
– Remove throttle valve module -GX3- ⇒ a4.3 nd installing
throttle valve moduleGX3”, page 484 .
CAUTION
– Unscrew union nuts -arrows- and detach high-pressure pipe.

Installing
Note
The high-pressure pipe does not need to be renewed after dis‐

assembly.
– Lubricate thread of union nuts with clean engine oil.

– Hand-tighten union nuts for high-pressure pipe (make sure
that pipe is not under stress).
Note
Use an open-end wrench to counterhold at the hexagon on

the high-pressure pump when tightening to the final specified
torque.
– Tighten union nuts using torque wrench -V.A.G 1331- and

suitable insert from tool set -T10395B-.
– Install throttle valve module -GX3- ⇒ a4.3 nd installing throt‐
tle valve moduleGX3”, page 484 .
Specified torques
♦ ⇒ o7.1 verview - high-pressure pump”, page 519

8 Lambda probe
⇒ o8.1 verview - Lambda probe”, page 530
⇒ a8.2 nd installing Lambda probe”, page 531
8.1 Assembly overview - Lambda probe
Note
♦ New lambda probes are coated with an assembly paste.

This paste must not get into the slots on the Lambda probe
body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste
⇒ Electronic parts catalogue.
♦ During installation, it is essential that wiring of lambda probe
is reattached in same positions. The wire must be prevented
from touching the exhaust pipe.

1 - Lambda probe 1 after cat‐

alytic converter -GX7-
❑ Consisting of:
Lambda probe after cat‐
alytic converter -G130-
Lambda probe 1 heater

after catalytic converter
-Z29-
ling Lambda probe 1
after catalytic conver‐
terGX7”, page 533
❑ 55 Nm
❑ For Lambda probe 1 af‐
ter catalytic converter -
GX7-.
❑ For Lambda probe
1 before catalytic con‐
verter -GX10-.
❑ Consisting of:
Lambda probe -G39-
Lambda probe heater -

Z19-
ling Lambda probe 1
before catalytic conver‐
❑ 55 Nm
8.2 Removing and installing Lambda probe

⇒ a8.2.1 nd installing Lambda probe 1 before catalytic conver‐
⇒ a8.2.2 nd installing Lambda probe 1 after catalytic conver‐
terGX7”, page 533
8.2.1 Removing and installing Lambda probe

1 before catalytic converter -GX10-
Lambda probe 1 before catalytic converter -GX10- consists of
♦ Lambda probe -G39-
♦ Lambda probe heater -Z19-
8. Lambda probe 531

♦ Lambda probe open ring spanner set -3337-
Removing
– Disconnect connector -2- for Lambda probe 1 before catalyt‐

ic converter -GX10-.
– Unscrew Lambda probe 1 before catalytic converter -GX10-
-2- using tool from Lambda probe open ring spanner set
-3337-.
Installing

Note

body.
Vehicles as of July 2015

• The following function should only be performed if it is
present in the vehicle diagnostic tester.
• If the function is not available, adaption need not be carried
out.
– If lambda probe has been renewed, erase learnt values and
adapt lambda probe to engine control unit using ⇒ vehicle
diagnostic tester.
♦ 0001 - Lambda probe adaption
Specified torques
♦ ⇒ o8.1 verview - Lambda probe”, page 530
8.2.2 Removing and installing Lambda probe

1 after catalytic converter -GX7-
Lambda probe 1 after catalytic converter -GX7- consists of
♦ Lambda probe after catalytic converter -G130-
♦ Lambda probe 1 heater after catalytic converter -Z29-
♦ Lambda probe open ring spanner set -3337-
8. Lambda probe 533

Removing
– Disconnect connector -1- for Lambda probe 1 after catalytic

converter -GX7-.
– Unscrew lambda probe 1 after catalytic converter -GX7- -1-
using a suitable tool from lambda probe open ring spanner
set -3337-.
Installing
Note

body.
Vehicles as of July 2015

• The following function should only be performed if it is
present in the vehicle diagnostic tester.
• If the function is not available, adaption need not be carried
out.
– If lambda probe has been renewed, erase learnt values and
adapt lambda probe to engine control unit using ⇒ vehicle
diagnostic tester.


♦ 0001 - Lambda probe adaption
Specified torques
♦ ⇒ o8.1 verview - Lambda probe”, page 530
8. Lambda probe 535

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ o1.1 verview - silencers”, page 536
⇒ e1.2 xhaust pipes from silencers”, page 546
⇒ a1.3 nd installing silencer”, page 550
⇒ p1.4 osition of clamp”, page 559
⇒ e1.5 xhaust system free of stress”, page 560
⇒ e1.6 xhaust system for leaks”, page 567
1.1 Assembly overview - silencers

⇒ o1.1.1 verview - silencers, Golf Cabriolet and Scirocco”, page
536
⇒ o1.1.2 verview - silencer, CC”, page 538
⇒ o1.1.3 verview - silencers, Sharan”, page 540
⇒ o1.1.4 verview - silencers, Tiguan”, page 542
⇒ o1.1.5 verview - silencer, T-Roc 2018, Golf 2020, Golf Estate
2021”, page 544
1.1.1 Assembly overview - silencers, Golf Cabriolet and Scirocco
536 Rep. gr.26 - Exhaust system

1 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
silencer”, page 550
❑ Separating exhaust
pipes from silencers ⇒
e1.2 xhaust pipes from
silencers”, page 546
❑ Aligning exhaust sys‐
tem free of tension
⇒ e1.5 xhaust system
free of stress”, page
560 .
2 - Mounting
3 - Bolt
❑ 20 Nm
4 - Retainer
5 - Rear clamp
❑ Align exhaust system
free of tension be‐
fore tightening ⇒
e1.5 xhaust system
560 .
❑ Installation position ⇒
p1.4 osition of clamp”,
page 559
page 537 Volkswagen Technical Site: https://vwts.ru
6 - Mounting
7 - Retainer
8 - Bolt
❑ 20 Nm
9 - Nut
❑ 20 Nm
10 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Removing and installing ⇒ a1.3 nd installing silencer”, page 550
❑ Separating exhaust pipes from silencers ⇒ e1.2 xhaust pipes from silencers”, page 546
❑ Aligning exhaust system free of tension ⇒ e1.5 xhaust system free of stress”, page 560 .
Specified torque for clamp
1. Exhaust pipes and silencers 537

Variante A - 25 Nm
Variante B - 30 Nm
1.1.2 Assembly overview - silencer, CC

1 - Clamping sleeve
page 559
page 539
2 - Mounting
3 - Fixture for mounting
❑ To body
❑ Bolt 25 Nm
4 - Centre silencer
tem free of tension
560 .
5 - Mounting
6 - Separating point for re‐
pairs
❑ Marked by indentation
on exhaust pipe.
❑ Cut through exhaust
pipe perpendicularly at
separating point for re‐
pairs using chain pipe
cutter -VAS 6254- ⇒
e1.2.1 xhaust pipes/si‐
lencers, CC”, page
546 .
7 - Rear silencer
8 - Mounting
9 - Mounting
10 - Bracket
❑ To body
❑ Bolt 25 Nm

Variante A - 25 Nm
Variante B - 30 Nm
1.1.3 Assembly overview - silencers, Sharan

1 - Clamping sleeve
page 559
❑ Specified torque ⇒ Fig.
““Specified torque for
clamp”“, page 541
2 - Centre silencer
tem free of tension
560 .
3 - Separating point for re‐
pairs
❑ Marked by indentation
on exhaust pipe.
❑ Cut through exhaust
pipe perpendicularly at
separating point for re‐
pairs using chain pipe
cutter -VAS 6254-.
4 - Centre pipe
5 - Clamping sleeve
page 559
6 - Mounting
7 - Rear silencer
8 - Mounting
9 - Mounting

Variante A - 25 Nm
Variante B - 30 Nm
1.1.4 Assembly overview - silencers, Tiguan

1 - Clamping sleeve
page 559
page 543
2 - Mounting
3 - Bolt
❑ 25 Nm
4 - Centre silencer and rear
silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
tem free of tension
560 .
5 - Right mounting
6 - Bolt
❑ 25 Nm
7 - Bolt
❑ 25 Nm
8 - Left exhaust hanger
9 - Mounting
10 - Nut
❑ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody cladding; Assembly overview - underbody
cladding
11 - Nut
cladding
12 - Tunnel cross-piece
cladding

Variante A - 25 Nm
Variante B - 30 Nm
1.1.5 Assembly overview - silencer, T-Roc 2018, Golf 2020, Golf Estate 2021

1 - Clamping sleeve
❑ Align exhaust system
free of tension be‐
fore tightening ⇒
e1.5 xhaust system
560 .
page 559
2 - Front silencer
❑ Front and rear silenc‐
ers are combined in
one unit when fitted in
the factory Renew sep‐
arately for repair purpo‐
ses.
tem free of tension
560 .
3 - Retainer
4 - Bracket
❑ For mounting
5 - Bolt
❑ 23 Nm
6 - Bracket
❑ For mounting
7 - Bolt
❑ 23 Nm
8 - Retainer
9 - Rear silencer
❑ Front and rear silencers are combined in one unit when fitted in the factory Renew separately for
repair purposes.
❑ Separating exhaust pipes from silencers ⇒ e1.2 xhaust pipes from silencers”, page 546
10 - Clamping sleeve
❑ For repair cases

❑ Align exhaust system free of tension before tightening ⇒ e1.5 xhaust system free of stress”, page
560 .
❑ Installation position ⇒ p1.4 osition of clamp”, page 559
❑ Specified torque ⇒ Fig. ““Specified torque for clamp”“, page 546
Pfeil - Coupling point of exhaust system

Variante A - 25 Nm
Variante B - 30 Nm
1.2 Separating exhaust pipes from silenc‐

ers
⇒ e1.2.1 xhaust pipes/silencers, CC”, page 546
⇒ e1.2.2 xhaust pipes/silencers, Tiguan, Sharan”, page 548
⇒ e1.2.3 xhaust pipes/silencers, Scirocco, Golf Cabriolet, Scir‐
occo, Golf Cabriolet, T-Roc, Golf. Golf Estate”, page 549
1.2.1 Separating exhaust pipes/silencers,

CC
♦ Chain pipe cutter -VAS 6254-

♦ The connecting pipe can be cut through at the separating

point for repairs in order to renew the centre and rear silenc‐
ers separately.
♦ The separating point for repairs is marked by an indentation
on the circumference of the exhaust pipe.
♦ The separating point for repairs is located in the area of the
rear axle.
– Remove underbody cover on rear axle ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Underbody cover.
– Cut silencer at right angles at the mark -Arrow 2- on the rear
silencer.
– Cut through exhaust pipe at separating point for repairs

-arrow- using chain pipe cutter -VAS 6254-.
– Install exhaust pipes/silencers ⇒ a1.3 nd installing silencer”,

page 550 .
– Cut through exhaust pipe perpendicularly at separating
point.
– Note installation position of clamp ⇒ p1.4 osition of clamp”,
page 559 .
– Checking exhaust system for leaks ⇒ e1.6 xhaust system for
leaks”, page 567 .
– Align exhaust system free of stress ⇒ e1.5 xhaust system
free of stress”, page 560 .
– Align tailpipes ⇒ e1.5.2 xhaust system such that it is not
under stress, CC”, page 561 .

1.2.2 Separating exhaust pipes/silencers, Ti‐

guan, Sharan
♦ The connecting pipe can be cut through at the cutting loca‐
tion in order to renew the centre and rear silencers separate‐
ly.
♦ Cutting location is marked by an indentation on the circum‐
ference of exhaust pipe.
♦ For individual renewal of the rear silencer, a cutting point is
provided in the connecting pipe.
♦ Cutting location is marked by an indentation on the circum‐
ference of exhaust pipe.
– Cut through exhaust pipe at separating point for repairs -2-
using chain pipe cutter -VAS 6254-.
– Install exhaust pipes/silencers ⇒ a1.3 nd installing silencer”,

page 550 .
– Cut through exhaust pipe perpendicularly at separating
point.
– Note installation position of clamp ⇒ p1.4 osition of clamp”,
page 559 .
– Checking exhaust system for leaks ⇒ e1.6 xhaust system for
leaks”, page 567 .
– Align tailpipes ⇒ e1.5.4 xhaust system free of stress, Shar‐
an”, page 564 .

1.2.3 Separating exhaust pipes/silencers,

Scirocco, Golf Cabriolet, Scirocco, Golf
Cabriolet, T-Roc, Golf. Golf Estate
Note
♦ Coupling points are provided to allow for renewing the si‐

lencers separately ⇒ o1.1 verview - silencers”, page 536 .
♦ Coupling points are marked by an indentation on circumfer‐
ence of exhaust pipe.
Procedure
– Cut through exhaust pipe perpendicularly at corresponding

separating point -arrow- using chain pipe cutter -VAS 6254-.
– Position clamp centrally at side marks -arrows- when instal‐
ling.

– Install clamp ⇒ p1.4 osition of clamp”, page 559 .

1.3 Removing and installing silencer

⇒ a1.3.1 nd installing silencer, Golf Cabriolet”, page 550
⇒ a1.3.2 nd installing silencer, CC”, page 551
⇒ a1.3.3 nd installing silencer, Tiguan”, page 554
⇒ a1.3.4 nd installing silencer, Sharan”, page 555
⇒ a1.3.5 nd installing silencers, Scirocco”, page 556
⇒ a1.3.6 nd installing silencers, T-Roc, Golf, Golf Estate”, page
558
1.3.1 Removing and installing silencer, Golf

Cabriolet
Removing
– Unscrew bolts -1- to -4- and remove both diagonal struts.
– Remove rear tunnel cross-piece -2-.
– Loosen bolt connections for front clamp -arrow-.

CAUTION
Risk of accident caused by high weight of silencers.
– Seek help from a second a mechanic for the following
work.
– Detach exhaust hanger -2-, and unscrew bolts -3- and -4-.
Remove silencer -1-.
Installing
Specified torques
♦ ⇒ o1.1.1 verview - silencers, Golf Cabriolet and Scirocco”,
page 536
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66; Under‐
body cladding; Assembly overview - underbody cladding.
1.3.2 Removing and installing silencer, CC


Note
To allow for removing the silencers without having to remove

the rear axle, the rear silencer must be cut off.
Removing
– If fitted, remove rear left underbody trim ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Underbody trim; Assembly over‐
view - underbody panels.
– Remove rear left vehicle level sender -G76- ⇒ Running gear,
axles, steering; Rep. gr. 43; Vehicle level sender; Removing
and installing rear vehicle level sender -G76-/-G77-.
– Remove bolts -2- and position vehicle level sender so that it

does not become damaged.
– Loosen clamp -arrow-, and push it to rear.

CAUTION
work.
– Unscrew bolts -1- for bracket, and detach exhaust hanger

-2-.
– Remove tunnel cross-piece -1-, and unscrew bolt -2-.
– Push exhaust system towards rear. Cut through rear silencer

at right angles at separating point -arrow- using chain pipe
cutter -VAS 6254-.
– Remove rear silencer towards rear. Remove front silencer

with centre silencer towards front.
Installing
– Position clamp for rear silencer centrally at side marks
-arrows- when installing.

– Turn clamp in such a way that there is sufficient clearance to

adjacent components.
– Install rear left vehicle level sender -G76- ⇒ Running gear,
axles, steering; Rep. gr. 43; Vehicle level sender; Removing
and installing rear vehicle level sender -G76-/-G77-.
Specified torques
♦ ⇒ o1.1.2 verview - silencer, CC”, page 538
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody cladding
1.3.3 Removing and installing silencer, Ti‐

guan
Removing
CAUTION
work.

– Remove rear tunnel cross member -7- ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Underbody cladding; Assembly
overview - underbody cladding.
– Detach centre and rear silencer -1- and -2- from brackets -6-
and -9-.

– Loosen clamp -3- and push to rear.

– Remove centre and rear silencer -1- and -2-.
Separating centre and rear silencers
– Release clamp -4- and remove rear silencer -1-.
Installing
Specified torques
♦ ⇒ o1.1 verview - silencers”, page 536
♦ Assembly overview - underbody covers ⇒ General body
repairs, exterior; Rep. gr. 66; Underbody cover; Assembly
overview - underbody covers.
1.3.4 Removing and installing silencer, Shar‐

an

Removing
CAUTION
work.
Removing rear silencer
– Loosen clamp -arrow-.

– Detach exhaust hangers -1, 2- and -3-.
– Remove rear silencer -A-.
Removing intermediate pipe
– Release clamp -arrow- and slide away.
– Guide out intermediate pipe on fuel tank.
Installing
– Make sure that the guide lug on rear right of bracket engag‐
es in recess in longitudinal member.
Specified torques
1.3.5 Removing and installing silencers,

Scirocco
– If necessary, separate exhaust pipe at separating point ⇒
e1.2 xhaust pipes from silencers”, page 546 .
– Position clamp centrally at side marks -arrows- when instal‐
ling.

Removing
– Remove rear tunnel cross member ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Assembly over‐
view - underbody cladding.
CAUTION
work.
– Unscrew nuts -arrows- of tunnel cross-piece -3-.

– Detach rubber mountings -4-.
– Unscrew bolts -2-, and remove silencer -1-.

Installing
Specified torques
1.3.6 Removing and installing silencers, T-

Roc, Golf, Golf Estate
Remove rear silencers -3- individually:
CAUTION
work.
– If necessary, separate silencer at coupling point ⇒

– After silencers have been separated, loosen clamps ⇒ Item
10 (page 545) .

– Support rear silencer -3- with engine and gearbox jack -VAS
6931-.
– Detach bracket -6-.
– Remove rear silencer -3-.
Remove front silencers -2- individually:
– Remove rear tunnel cross-piece ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding.
– If necessary, separate silencer at coupling point ⇒
– After silencers have been separated, loosen clamps ⇒ Item
10 (page 545) .
– Release clamping sleeve -1-, and slide it forwards.
– Support front silencer -2- with engine and gearbox jack -VAS
6931-.
– Detach bracket -8-.
– Detach front silencer -2-.
Installing
– Align holes of front bracket with the two markings in securing
strap of fuel tank.
Specified torques
♦ ⇒ o1.1.5 verview - silencer, T-Roc 2018, Golf 2020, Golf
Estate 2021”, page 544
cladding
1.4 Installation position of clamp

– Install clamping sleeve so that end of bolt -arrow- does not
extend beyond lower edge of clamping sleeve.

– Position clamp centrally at side marks -a- when installing.
– Turn clamp in such a way that there is sufficient clearance to

adjacent components.
– Tighten threaded connections evenly.
Specified torques
1.5 Aligning exhaust system free of stress

⇒ e1.5.1 xhaust system free of stress, Golf Cabriolet and Scir‐
occo”, page 560
⇒ e1.5.2 xhaust system such that it is not under stress, CC”,
page 561
⇒ e1.5.3 xhaust system free of stress, Tiguan”, page 562
⇒ e1.5.4 xhaust system free of stress, Sharan”, page 564
⇒ e1.5.5 xhaust system free of tension, T-Roc, Golf, Golf Es‐
tate”, page 566
1.5.1 Aligning exhaust system free of stress,

Golf Cabriolet and Scirocco
• The exhaust system must be aligned when cold.

Exhaust hanger at end of tunnel
– Push exhaust system towards front of vehicle until preload‐

ing at mounting for exhaust pipe -a- = 6 mm.
Align end exhaust pipes
– Align rear silencer so that there is an even distance -a- be‐

tween bumper cut-out and tailpipes.
– Dimension -b- is approx. 20 mm.
– Unfasten rear silencer mounting to align tailpipes.
1.5.2 Align exhaust system such that it is not

under stress, CC




Tiguan

Exhaust hanger on rear axle

Exhaust hanger on rear silencer


Installation position of retaining bracket
– Install retaining bracket in the position shown.



Sharan
Note
-Arrow- points in direction of travel.

Exhaust hanger on rear axle



Installation position of retaining bracket
– Install retaining bracket in the position shown.


1.5.5 Aligning exhaust system free of ten‐

sion, T-Roc, Golf, Golf Estate
Procedure
– Loosen threaded connections on clamps -arrow-.



– Tighten clamps ⇒ o1.1 verview - silencers”, page 536 .
– Make sure that there is sufficient clearance between exhaust
system and all components.
Specified torques
1.6 Checking exhaust system for leaks

– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

2 Emission control
⇒ o2.1 verview - emission control”, page 568
⇒ a2.2 nd installing catalytic converter”, page 570
⇒ a2.3 nd installing particulate filter”, page 577
2.1 Assembly overview - emission control

1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Nut
page 570
4 - Bolt
❑ 20 Nm
5 - Nut
page 570
6 - Bracket
7 - Bracket
8 - Bolt
page 570
9 - Bolt
page 570
10 - Front exhaust pipe with
catalytic converter
❑ Do not bend flexible
joint more than 10°.
Otherwise, it can be
damaged.
❑ Install flexible joint so
that it is not under tension
❑ Take care not to damage wire mesh on decoupling element.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ a2.2 nd installing catalytic converter”, page 570
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
11 - Screw-type clamp
12 - Seal
❑ Removing and installing ⇒ a2.2 nd installing catalytic converter”, page 570
13 - Turbocharger
14 - Nut
❑ 30 Nm
15 - Front clamping sleeve
❑ Align exhaust system free of tension before tightening ⇒ e1.5 xhaust system free of stress”, page 560 .
❑ Tighten threaded connections evenly.
2. Emission control 569

Installing catalytic converter - specified torque and sequence
1. – Fit catalytic converter to tur‐

bocharger and fit screw-type
clip -arrow- without tighten‐
ing
2. – Loosely screw in bolts -3, 5- • It should still be
and bolts -1, 2, 4- by hand possible to move
catalytic converter
and bracket.
3. – Tighten screw-type clip 15 Nm

-arrow-
4. – Tighten bolts and nuts in the 20 Nm
sequence -1 … 5-
2.2 Removing and installing catalytic con‐

verter
Note
The catalytic converter is removed together with the front ex‐

haust pipe.

♦ High-temperature paste ⇒ Electronic parts catalogue.
Removing
Note
Reinstall all cable ties in the same locations when installing.

and pull them off.

– Lay electrical wires to one side.

– Remove wires from heat shield of turbocharger.
– Unscrew bolts -arrows- on camshaft housing.
Note
♦ Do not loosen bolts on turbocharger.

♦ Coolant lines on turbocharger are not removed.
– Unscrew nuts and bolts -arrows-.

Note
♦ Prior to loosening the connection between the catalytic con‐

verter and the turbocharger, mark the position of the clamp
⇒ page 572 .
♦ Depending on the component that might need to be re‐
newed, a mark is to be made on the component opposite
to the component to be renewed.
♦ Make sure that the clamp is fitted at the same position on
reinstallation.
Clamp position
– Loosen bolt -1- until clamp -2- can be pushed in direction of

-arrow- over catalytic converter.
– Remove bolt -1- and nuts -arrows-.

– Unscrew bolts -arrows- of bracket.

– Unscrew right nut -arrow- of bracket.
– Unscrew nut -arrow- to the left of the bracket.
– Remove tunnel cross-piece ⇒ General body repairs, exteri‐

or; Rep. gr. 66; Underbody trim; Assembly overview - under‐
body trim panels.
– Detach connector from retainer and lay wire leading to
Lambda probe to one side.

Vehicles with front-wheel drive

– Remove catalytic converter with front exhaust pipe towards
rear.
Vehicles with all-wheel drive
– Remove both lambda probes ⇒ a8.2 nd installing Lambda

probe”, page 531 .
– Release and pull off electrical connector -1- on oil level and
oil temperature sender -G266-.

– Unbolt flexible coupling of propshaft -1- from bevel box

⇒ Rep. gr. 39; Propshaft; Removing and installing propshaft.
– Position engine support -T10533- as shown.
– Engine support -T10533/2- is positioned on flat bolt connect‐

ing point of engine support -T10533/1-.
– Screw in original bolt of pendulum support -2- in front threa‐
ded hole of pendulum support.
– Screw bolt M8 x 40 mm -1- with washer -2- into left threaded
hole of noise insulation.
– Tighten bolts by hand.
– Using engine support -T10533-, push engine as far forwards
as possible.
– Push propshaft -1- as far as stop in direction of -arrow-.

– Remove catalytic converter with front exhaust pipe -2- down‐
wards.

– Turn catalytic converter with front exhaust pipe accordingly

when doing this.
– Insert screwdriver -2- in recess -arrow- on turbocharger.

– Lever out seal -1-.
Installing
Note
♦ Renew seal and self-locking nuts.

♦ Coat studs and bolts of catalytic converter with high-temper‐
ature paste; high-temperature paste ⇒ Electronic parts cata‐
logue.
– Position catalytic converter on turbocharger and engine ⇒

page 570 .
– Align catalytic converter, turbocharger and clamp in relation
to each other as per the markings.
– If new parts are installed, markings must be transferred.

Specified torques

2.3 Removing and installing particulate fil‐

ter
Note
♦ The removal and installation procedure for the particulate

filter is the same as that for the catalytic converter. There‐
fore, only removal and installation of the catalytic converter
is described ⇒ a2.2 nd installing catalytic converter”, page
570 .
♦ If the particulate filter was renewed, the ash load must be
reset using ⇒ Vehicle diagnostic tester.

28 – Ignition system
1 Ignition system
⇒ o1.1 verview - ignition system”, page 578
⇒ a1.2 nd installing ignition coils with output stage”, page 580
⇒ a1.3 nd installing knock sensor 1G61”, page 583
⇒ a1.4 nd installing Hall sender”, page 584
⇒ a1.5 nd installing engine speed senderG28”, page 585
1.1 Assembly overview - ignition system
578 Rep. gr.28 - Ignition system

1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 20 Nm
2 - Knock sensor 1 -G61-
knock sensor 1G61”,
page 583
3 - Spark plug
❑ For latest spark plugs,
see ⇒ Electronic parts
catalogue (ETKA)
❑ Remove and install with
spark plug socket and
extension -3122 B-
❑ Specified torque:
22 Nm
❑ Change interval
⇒ Maintenance tables
4 - Ignition coil with output
stage and spark plug connec‐
tors
Note
Ignition coils with output stage and

spark plug connectors are availa‐
ble individually for repairs ⇒ Elec‐
tronic parts catalogue (ETKA)

❑ To remove, use puller -T10530-.
❑ Removing and installing ⇒ a1.2 nd installing ignition coils with output stage”, page 580
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
❑ Removing and installing ⇒ a1.4.1 nd installing Hall senderG40”, page 584
1. Ignition system 579

8 - O-ring
9 - Bolt
❑ 8 Nm
10 - Hall sender 3 -G300-
❑ Removing and installing ⇒ a1.4.2 nd installing Hall sender 3G300”, page 584
❑ Only installed in vehicles with exhaust camshaft adjuster
11 - O-ring
12 - Sender wheel
❑ For engine speed sender -G28-
13 - Sealing flange, gearbox side
14 - Engine speed sender -G28-
❑ Removing and installing ⇒ a1.5 nd installing engine speed senderG28”, page 585
15 - Bolt
❑ 4.5 Nm
1.2 Removing and installing ignition coils

with output stage
♦ Puller -T10530-
Note
♦ The ignition coils are easier to remove when the engine is

warm.
♦ The grease used upon assembly in the factory makes it
easier to remove ignition coils or the spark plug connectors
when the engine is warm.
♦ When installing used ignition coils with output stage, the igni‐
tion coils must be lubricated with silicone paste ⇒ Electronic
parts catalogue (ETKA).
♦ Ignition coils with output stage and spark plug connectors
are available individually for repairs ⇒ Electronic parts cata‐
logue (ETKA)

Removing
Ignition coils “cyl. 2, 3 and 4”:
All ignition coils (continued):

– Push puller -T10530- as far as stop into hole in ignition coil
-1-.
– Tighten knurled nut -2- in -direction of arrow-.

– Pull ignition coil out of camshaft housing in
-direction of arrow- using puller -T10530-.

Installing
Note
♦ Ignition coils with output stage and spark plug connectors

are available individually for repairs ⇒ Electronic parts cata‐
logue (ETKA)
♦ The spark plug connectors are removed from the ignition
coils by hand.
♦ When installing used ignition coils with output stage, the igni‐
tion coils must be lubricated with silicone paste ⇒ Electronic
parts catalogue (ETKA).
– Apply a thin bead of silicone paste around sealing hose of

ignition coil.
– Slide spark plug connector -1- by hand onto ignition coil as

far as stop.

The vent drilling -2- must be centred relative to connector hous‐

ing -3- while doing so.
– Insert all spark plugs with spark plug connector loosely into
spark plug recess.
– Align ignition coils with connectors and simultaneously push
all connectors onto ignition coils.
– Press ignition coils evenly onto spark plugs by hand (do not
use tools).
Specified torques
1.3 Removing and installing knock sensor

1 -G61-
Removing
conditioner compressor; Assembly overview - air conditioner
compressor drive unit.
– Unscrew bolt -2- and remove knock sensor 1 -G61-.

Installing


ing; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
Specified torques
1.4 Removing and installing Hall sender

⇒ a1.4.1 nd installing Hall senderG40”, page 584
⇒ a1.4.2 nd installing Hall sender 3G300”, page 584
1.4.1 Removing and installing Hall sender -

G40-
Removing
– Unscrew bolt -2- and remove Hall sender -G40-.

Installing
– Install in reverse order of removal.
Specified torques
1.4.2 Removing and installing Hall sender 3

-G300-
Only installed in vehicles with adjustable exhaust camshaft (en‐
gine codes: CZDA, DJKA).
Removing

– Unscrew bolt -2- and remove Hall sender 3 -G300-.

Installing
Specified torques
1.5 Removing and installing engine speed

sender -G28-
♦ Socket, 4 mm -T10370-
Removing
insulation.
– Unscrew bolt -arrow- and push charge air cooling pump
-V188- to one side.

– Unscrew bolt -2- and remove engine speed sender -G28-.

Installing
insulation.
Specified torques

Engine Czca Czda CZDB Djka CZDC Repair Manual Eng

Uploaded by

Copyright:

Available Formats

Engine Czca Czda CZDB Djka CZDC Repair Manual Eng

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Czca Czda CZDB Djka CZDC Repair Manual Eng

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

3.4 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with start/stop system

1.4 Safety precautions when working on the cooling system

1.5 Safety precautions when working on ignition system

Risk of damage to components

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Fitting locations of vehicle data sticker ⇒ Maintenance; Booklet ;

Engine code CZDA CZDB CZDC CZCA DJKA

Engine code CZDA CZDB CZDC CZCA DJKA

Volkswagen Technical Site: https://vwts.ru

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 General information

3.3 General repair instructions

3.3.1 General notes on injection

♦ Do not use sealants containing silicone. Particles of silicone

3.3.2 General notes on ignition system

3.3.3 General notes on charge air system

6 Rep. gr.00 - Technical data

♦ After installing turbocharger, run engine for about 1 minute

3.4 Foreign objects in engine

3.5 Contact corrosion

3.6 Routing and attachment of lines

3.7 Fitting radiator and condensers

3.8 Checking vacuum system

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing motor

1.1.1 Removing engine, Golf Cabriolet and

♦ Extension -2024 A /1- of lifting tackle -2024 A-

1. Removing and installing motor 9

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

♦ Engine support -T10497-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Spring-type clip pliers -VAS 6362-

10 Rep. gr.10 - Removing and installing engine

♦ Engine and gearbox jack -VAS 6931-

♦ Locking pin -T10060 A-

♦ Engine bung set -VAS 6122-

♦ Commercially available stepladder

♦ The engine is removed downwards together with the gear‐

– Open filler cap -1- on coolant expansion tank.

1. Removing and installing motor 11

– Remove air filter housing ⇒ a3.2 nd installing air filter hous‐

– Unclip upper part -2- of air duct, and remove it.

12 Rep. gr.10 - Removing and installing engine

– Move lines to one side.