Engine Cpta Czca Czea Ea211 Eng

Service
Workshop Manual
Polo 2010 ➤
Polo 2014 ➤
Polo Lim RUS 2016 ➤
4-cyl. direct injection (1.4 l, 4V, EA 211, turbocharger)
Engine ID
CPT CZC CZE
A A A
Edition 11.2018
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.
Polo 2010 ➤ , Polo 2014 ➤ , Polo Lim RUS 2016 ➤
4-cyl. direct injection (1.4 l, 4V, EA 211, turbocharger) - Edition 11.2018
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 a 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 instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Contents i
4.5 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7 Setting piston to TDC position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.4 Preassembling and installing valve timing tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.7 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.8 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.4 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.6 Removing and installing exhaust camshaft control valve 1 N318 . . . . . . . . . . . . . . . . . . . . 179
3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.8 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 205
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 215
4.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.5 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 218
ii Contents
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.7 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 245
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 248
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 250
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 263
4.5 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 277
1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.5 Removing and installing air intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3.3 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Contents iii
4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
5.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.3 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
6.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 323
6.2 Removing and installing engine (motor) control unit J623 with protective housing . . . . . . 324
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.3 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.5 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
iv Contents
00 – Technical data
1 Safety information
(VRL012422; Edition 11.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “1.4 Safety precautions when working on the cooling system”,
page 2
⇒ “1.5 Safety precautions 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 connection
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 a start/stop system

Risk of injury due to unexpected motor start
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
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 instru‐
ments
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 equip‐
ment on the rear seat.
1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
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 run‐
ning. 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 elec‐
tric cables.
– Switch off the ignition before washing the engine.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

The engine code and the engine number can be found 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 (alphanumeric).
The first part (maximum 3 characters) makes up the “engine
code”, and the second part (6 characters), the “serial number”.
After 999,999 engines with the same code letters have been pro‐
duced, 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 letter
“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, depending on the engine control unit - J623- .
The four-digit engine code can be found on the identification plate,
the vehicle data sticker and the engine control unit.
Note
Fitting locations of the vehicle data sticker ⇒ Maintenance ; Book‐

let ; Vehicle data sticker .
Engine code CPTA CZCA CZEA

Manufactured 06.12 ► 05.16 ► 05.14 ►
Exhaust emission standard EU5 EU6 EU6
Displacement cm3 1395 1395 1395
Power kW at 103/4500-6000 92/5000-6000 110/5000-6000
rpm
Torque Nm at 250/1500-3500 200/1400-4000 250/1500-3500
rpm
Bore ∅ mm 74.5 74.5 74.5
Stroke mm 80.0 80.0 80.0
Compression ratio 10.5 10.0 10.0
Valves per cylinder 4 4 4
RON min. 95 unleaded1 95 unleaded1 95 unleaded1
Injection, ignition system Motronic ME 17 Motronic ME 17 Motronic ME 17
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Volkswagen Technical Site: http://vwts.ru http://vwts.info

1) In exceptional circumstances min. 91 RON, however with re‐
duced performance.
2. Identification 3
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 Foreign objects in engine”, page 4
⇒ “3.3 Contact corrosion”, page 4
⇒ “3.4 Routing and attachment of lines”, page 4
⇒ “3.5 Fitting radiator and condensers”, page 5
3.1 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ 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 fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
3.2 Foreign objects in engine

Prevent the ingress of foreign bodies. When carrying out instal‐
lation work on the engine, open channels must be sealed with
suitable plugs such as those from the engine bung set - VAS
6122- .
3.3 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 .
3.4 Routing and attachment of lines

♦ Avoid interchanging and ensure that the original installation
position is restored. Mark the lines for the fuel, hydraulic and
vacuum systems and for the activated charcoal filter system
as well as electrical 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.
4 Rep. gr.00 - Technical data

3.5 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 per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents.
3. Repair instructions 5
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 6
⇒ “1.2 Separating engine and gearbox”, page 15
⇒ “1.3 Securing engine on engine and gearbox support”,
page 16
⇒ “1.4 Installing engine”, page 17
1.1 Removing engine
Special tools and workshop

equipment required
♦ Release lever - 80 - 200-

♦ 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-
6 Rep. gr.10 - Removing and installing engine

♦ Commercially available stepladder

♦ Safety glasses
♦ Safety gloves
Removing
Note
♦ The engine is removed downwards together with the gearbox.

♦ Reinstall all cable ties in the same locations when installing.
– Carefully open filler cap -1- on coolant expansion tank -2- in

-direction of arrow-.
CAUTION
Skin and other parts of the body may be scalded.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

27 ; Battery; Removing and installing battery tray .
Vehicles with manual gearbox

– Pull vacuum line -1- off brake servo -2-.
– If fitted, release and disconnect connector on vacuum sender

on vacuum line.
Continued for all vehicles
– Remove air filter housing
⇒ “3.2 Removing and installing air filter housing”, page 308 .
– Carefully loosen wiring harness at its fastening points

-arrows-.
1. Removing and installing engine 7

– Release connector -arrow-, pull off and unclip from bracket.

– Release connector from engine control unit and pull off
⇒ “6 Engine control unit”, page 323 .
– Place wiring harness on engine.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation .
– Remove front left and right wheel housing liners ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– If fitted, release and pull off connector -1- on oil level and oil
temperature sender - G266- .
– Move clear electrical wiring harness, and lay it to one side.
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft heat shield .
– Remove left and right drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Remove radiator cowl
⇒ “4.5 Removing and installing radiator cowl with radiator fan”,
page 267 .
– Attach protective mat - VAS 531003- to vehicle as shown in

illustration.
– Drain coolant
⇒ “1.3 Draining and adding coolant”, page 225 .
Vehicles with air conditioner compressor:
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
– Remove poly V-belt

⇒ “1.3 Removing and installing poly-V belt”, page 38 .
– Separate connector -1- on air conditioning compressor regu‐
lating valve - N280- .
– Remove air conditioner compressor with refrigerant lines con‐
nected from engine ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor; Removing air conditioner com‐
pressor from and installing to bracket .
– 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.


– Loosen clamp -arrow-, and push it to rear.
– Detach exhaust hangers -3- in -direction of arrow- from sub‐

frame -2-.
– Lower exhaust system -1- until it rests on subframe -2-.
– Unscrew bolt -2-.

– Remove screw-type clip -1-.
– Unscrew nuts -arrows- and tie up catalytic converter -3-.
– Unscrew bolts -arrows- and remove bracket -1-.

– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.
– Open spring-type clips -arrows-.

– Pull coolant hose -1- off radiator -2-.

– Pull coolant hoses -1- off water radiator for charge air cooling
circuit -2-.
– Release retaining clips -arrows-.

– Pull coolant hoses -1- off heat exchanger for heater unit.

– Release and pull off connector -2- on starter -1-.

– Pull off protective cap -3-.
– Unscrew nut -arrow- and remove line from starter -1-.
– Release and pull off connectors -2-.

– Unclip connectors -2- from bracket -1-.
– Unclip wires -3- and -4- from bracket -1-.
– Unscrew nuts -arrow-.
– Remove bracket -1- from gearbox.
– Release and pull off connector -3- on alternator -2-.

– Unscrew nut -4-.
– Remove wire -1- from alternator -2-.
– Lay wiring harness -1- on coolant hose to one side.
– Lay lower wiring harness on intake manifold to one side.

– Use removal lever - 80 - 200- to do this.
– Release and pull off connectors on gearbox.
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
nism; Removing and installing clutch slave cylinder .

Vehicles with dual clutch gearbox

– Release catch -arrow- and disconnect vacuum hose -1-.
– Move clear vacuum hose at air intake pipe -2-.
– Remove selector lever cable -1- ⇒ Rep. gr. 34 ; Removing

and installing gearbox .
– Unscrew bolts -2- on gearbox.
– Lay selector lever cable with retainer to one side.
– Release and pull off connector -1- of mechatronic unit in

– Unscrew bolts -2- and -3-.
– Remove retainer with wiring harness and lay them to one side.
– Pull vacuum line -2- in direction of -arrow- off vacuum pump

for brakes - V192- -1-.
– Lay vacuum line -1- to one side.


– Release connectors -2- and pull off.
– Unscrew securing bolts -3-.
– Place coolant expansion tank -1- on engine.
– Disconnect fuel supply line -1- and line to activated charcoal

filter solenoid valve 1 - N80- -2-. Disconnect plug-in connec‐
tors ⇒ Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-
in connectors .
– Unscrew earth wire -1-.

– Unscrew bolts -arrows- on engine mounting approx. 2 turns.
– Unscrew securing bolts -arrows- on gearbox mounting by ap‐

prox. 2 turns.
– Remove pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 28 .
– Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration.

– Position engine support T10497 with pin T10497/1 on cylinder

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 - V.A.G 1383 A- in engine sup‐
port T10497 , and raise engine/gearbox assembly slightly.
Note
To unscrew bolts for assembly mounting use commercially avail‐

able stepladder.
– Remove bolts -arrows- for engine mounting.
– Unscrew securing bolts -arrows- from gearbox mounting.

– Check that all vacuum lines and electrical wiring between en‐
gine, 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 forwards
and only then lower further.

1.2 Separating engine and gearbox

Special tools and workshop equipment required
♦ Shackle - 10 - 222 A /12-
♦ Hook - 10 - 222 A /2-
♦ Workshop hoist - VAS 6100-
Procedure
• 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 gearbox

support
♦ Engine and gearbox support - VAS 6095-

♦ Workshop hoist - VAS 6100-
Procedure
• Gearbox detached from engine
⇒ “1.2 Separating engine and gearbox”, page 15 .
– Secure lifting tackle - 2024 A- on engine, and attach it to work‐
shop hoist - VAS 6100- as shown in illustration.
Note
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-.
– 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

Install in reverse order of removal. The following should be ob‐
served:
• Attach engine/gearbox assembly 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 .
♦ Reinstall all cable ties in the same locations when installing.
When the gearbox has been separated from the engine:

– Install intermediate plate ⇒ page 52 .

– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
Installing engine/gearbox assembly in vehicle:
– Take up engine/gearbox assembly with engine support
T10497 .
– Guide engine/gearbox assembly into body.
– Install engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 26 .
– Install gearbox mounting
⇒ “2.3 Removing and installing gearbox mounting”,
page 27 .
– Detach engine support T10497 from engine.
– Install pendulum support
⇒ “2.4 Removing and installing pendulum support”,
page 28 .
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐
lector mechanism; Assembly overview - selector cables .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install poly V-belt
– Connect wires to engine control unit - J623-
⇒ “6 Engine control unit”, page 323 .
– Connect wires to alternator ⇒ Electrical system; Rep. gr. 27 ;
Alternator; Assembly overview - alternator .
– Ensure proper electrical connections and routing ⇒ Electrical
system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics
boxes; Overview of fitting locations – relay carriers, fuse car‐
riers, electronics boxes and ⇒ Current flow diagrams, Electri‐
cal fault finding and Fitting locations.
– Install catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 343 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Install coolant expansion tank
⇒ “4 Radiator, radiator fan”, page 257 .
– Install radiator cowl
page 267 .
– Install air filter housing
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .

– Install wheel housing liners ⇒ General body repairs, exterior;

Rep. gr. 66 ; Wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres; Specified torque for wheel bolts .
– Add coolant ⇒ page 227 .
Torque settings
Note
♦ The specified torques are only valid for nuts and bolts which
have been slightly greased, oiled, phosphate-treated or black-
oxided.
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 21

♦ Securing gearbox on engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Specified torques for gearbox .
Component Nm
Bolts and nuts M6 9
M7 15
M8 20
M10 40
M12 65

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 21
⇒ “2.2 Removing and installing engine mounting”, page 26
⇒ “2.3 Removing and installing gearbox mounting”, page 27
⇒ “2.4 Removing and installing pendulum support”, page 28
⇒ “2.5 Supporting engine in installation position”, page 30
2.1 Assembly overview - assembly mount‐

ings
⇒ “2.1.1 Assembly overview - assembly mountings, manual gear‐
box”, page 21
⇒ “2.1.2 Assembly overview - assembly mountings, dual clutch
gearbox”, page 23
2.1.1 Assembly overview - assembly mountings, manual gearbox
1 - Engine support
❑ Removing and installing
⇒ “1.6 Removing and in‐
stalling engine support”,
page 43
❑ Specified torque and
tightening sequence
⇒ page 23
2 - Bolt
❑ Renew after removal
tightening sequence
⇒ page 23
3 - Engine mounting
stalling engine mount‐
ing”, page 26
❑ Aligning engine mount‐
ing ⇒ page 22
4 - Bolt
❑ 20 Nm + 90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth
wire.
❑ 30 Nm + 90°
7 - Bolt
❑ Qty. 2
2. Assembly mountings 21
❑ 30 Nm + 90°
8 - Bolt
❑ 40 Nm + 90°
❑ Tightening sequence ⇒ page 23
9 - Gearbox mounting
❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mounting”, page 27
❑ Tightening sequence - gearbox mounting ⇒ page 23 .
10 - Bolt
❑ 50 Nm + 90°
11 - Bolt
❑ 50 Nm + 90°
❑ Qty. 2
12 - Pendulum support
❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 28
13 - Bolt
❑ 40 Nm + 90°
14 - Bolt
❑ 30 Nm + 90°
❑ Qty. 3
15 - Bolt
❑ 50 Nm + 90°
Aligning engine mountings:

– Fit engine mounting on longitudinal member.
Note
Risk of damage to threads by starting bolts at an angle.
• The positioning holes -arrows- must be in line; check with ap‐

propriate drill if necessary.

Engine support - specified torque and tightening sequence
Note
– Tighten bolts in stages in the sequence shown.

Stage Bolts Specified torque/turning further angle
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- Turn 90° further
Tightening sequence - gearbox mounting
Note
Ite Procedure Torque setting

m
B Start bolts before tightening hand-tight
an them
dC
B Tighten bolts 50 Nm + 90°
C Tighten bolt. 50 Nm + 90°
A Start bolts before tightening hand-tight
them
A Bolts 40 Nm + 90°
2.1.2 Assembly overview - assembly mountings, dual clutch gearbox
1 - Engine support
page 43
tightening sequence
⇒ page 25
2 - Bolt
tightening sequence
⇒ page 25
3 - Engine mounting
stalling engine mount‐
ing”, page 26
❑ Aligning engine mount‐
ing ⇒ page 25
4 - Bolt
❑ 20 Nm + 90°
❑ Qty. 4
5 - Nut
❑ The securing nut must
not be loosened.
6 - Centre hex stud
❑ With mounting for earth
wire.
❑ 30 Nm +90°
7 - Bolt Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Qty. 2
❑ 30 Nm + 90°
8 - Bolt
❑ 40 Nm + 90°
9 - Gearbox mounting
❑ Removing and installing ⇒ “2.3 Removing and installing gearbox mounting”, page 27
10 - Bolt
❑ 50 Nm + 90°
11 - Bolt
❑ 50 Nm + 90°
❑ Qty. 2

12 - Pendulum support
❑ Removing and installing ⇒ “2.4 Removing and installing pendulum support”, page 28
13 - Bolt
❑ 40 Nm + 90°
14 - Bolt
❑ 30 Nm + 90°
❑ Qty. 2
15 - Bolt
❑ 50 Nm + 90°
Aligning engine mountings:

– Fit engine mounting on longitudinal member.
Note

Engine support - specified torque and tightening sequence
Note
Risk of damage to threads by starting bolts at an angle:

1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
Tightening sequence - gearbox mounting

Ite Procedure Torque setting
m
B Start bolts before tightening hand-tight
an them
dC
B Tighten bolts 50 Nm + 90°
C Tighten bolt. 50 Nm + 90°
A Start bolts before tightening hand-tight
them
A Bolts 40 Nm + 90°
2.2 Removing and installing engine mount‐

ing
Removing
– Remove resonator for intake air
⇒ “3.3 Removing and installing resonator for intake air”, page
309 .

– Support engine in its installation position
⇒ “2.5 Supporting engine in installation position”, page 30 .
– Take up weight of engine/gearbox assembly slightly with spin‐
dle; do not lift.

– Unscrew nuts -3-.

– Remove earth wire.
Note
The securing nut -4- must not be loosened.
– Unscrew bolts -2- between engine mounting and engine.

– Unscrew bolts -arrows- and remove engine mounting.
Installing
served:
– Place assembly mounting on longitudinal member.

Note
♦ Risk of damage to threads by starting bolts at an angle.

♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
– Remove support bracket - 10 - 222 A- from engine.

Torque settings
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 307
2.3 Removing and installing gearbox

mounting
Removing
309 .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
dle; do not lift.
– Carefully loosen wiring harness at its fastening points

-arrows-.
– Unscrew securing bolts -arrows- from gearbox mounting.

Installing
served:
Note
– Remove support bracket - 10 - 222 A- from engine.

Torque settings
♦ Tightening sequence for gearbox mounting ⇒ page 23 .
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
2.4 Removing and installing pendulum sup‐

port
⇒ “2.4.1 Removing and installing pendulum support, manual
gearbox”, page 28
⇒ “2.4.2 Removing and installing pendulum support, dual clutch
gearbox”, page 29
2.4.1 Removing and installing pendulum sup‐

port, manual gearbox
♦ Torque wrench - V.A.G 1331-

Removing
– Unscrew bolts -arrows- for pendulum support -1-.
Note
Bolt -3- must not be loosened.
– Pull pendulum support -1- out of assembly carrier -2-.

Installing
served:
Note
♦ There are threaded inserts, e.g. “Heli coil” in the bolting holes
for the pendulum support.
♦ Identification: shoulder along beginning of thread -arrow-.
Torque settings
2.4.2 Removing and installing pendulum sup‐

port, dual clutch gearbox
Removing
– Unscrew bolts -arrows- for pendulum support.
Note
Bolt -1- must not be loosened.
– Pull pendulum support -1- out of assembly carrier -2-.

Installing
served:
Note
♦ There are threaded inserts, e.g. “Heli coil” in the bolting holes
for the pendulum support.
♦ Identification: shoulder along beginning of thread -arrow-.
Torque settings
2.5 Supporting engine in installation posi‐

tion

♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10 - 222 A /32-
♦ Tensioning strap - T10038-
To prevent damage to edges of wings, cover lower areas of both

adapters - 10 - 222 A /8- with woven adhesive tape -arrow- ⇒
Electronic Parts Catalogue (ETKA) .
Procedure
– Detach seals from upper edge of wing.

– Slide adapter - 10 - 222 A /32- onto engine support bracket -
10 - 222 A- as shown in illustration.
– Mount adapter - 10 - 222 A /8- on engine support bracket - 10
- 222 A- .
– Lift up plenum chamber cover at sides.
– Position engine support bracket - 10 - 222 A- on left and right
onto longitudinal members as shown in illustration.

– Do not position engine support bracket - 10 - 222 A- on edges

of wings.
– Fit adapter - 10 - 222 A /8- behind the hole -arrow- and align
it.
– Mount adapter - 10 - 222 A /32- to mountings on engine as
shown in illustration.
– Secure engine support bracket - 10 - 222 A- using tensioning
straps - T10038- on both sides of bonnet hinges.
dle; do not lift.
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
37
⇒ “1.3 Removing and installing poly-V belt”, page 38
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 40
⇒ “1.5 Removing and installing vibration damper”, page 41
⇒ “1.6 Removing and installing engine support”, page 43
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 45
1.1 Assembly overview - poly V-belt drive

⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without
air conditioner compressor”, page 34
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with air
conditioner compressor”, page 36
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
pressor
34 Rep. gr.13 - Crankshaft group

1 - Bolt
❑ 150 Nm +180°
❑ Use counter-hold tool -
T10475- to loosen and
tighten
2 - Vibration damper
stalling vibration damp‐
er”, page 41
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 39
stalling poly-V belt”,
page 38
❑ When installing, make
sure it is properly seated
on pulleys.
4 - Bolt
❑ 23 Nm
5 - Tensioning device for poly
V-belt
❑ Pivot with socket to
slacken poly V-belt
❑ Lock with locking pin -
T10060 A- .
❑ Removing and installing ⇒ “1.4 Removing and installing tensioner for poly V-belt”, page 40
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 alternator
1. Cylinder block (pulley end) 35

1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor
1 - Poly V-belt
❑ Check for wear
chalk or felt-tipped pen
❑ Do not kink
❑ Poly V-belt routing
⇒ page 40
⇒ “1.3.1 Removing and
installing poly V-belt, ve‐
hicles without air condi‐
tioner compressor”,
page 38
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Specified torque
⇒ Item 1 (page 35)
er”, page 41
4 - Tensioning device for poly
V-belt
❑ Pivot with socket to
slacken poly V-belt
❑ Lock with locking pin -
T10060 A- .
stalling tensioner for
poly V-belt”, page 40
5 - Bolt
❑ 23 Nm
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 alternator
8 - Dowel sleeve
❑ For air conditioner compressor.
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor
10 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor .

1.2 Assembly overview - sealing flange, belt pulley end
1 - Bolt
er”, page 41
3 - Seal
❑ For crankshaft on belt
pulley end
⇒ “1.7 Renewing crank‐
shaft oil seal - belt pulley
end”, page 45
❑ Do not oil
4 - Sealing flange at belt pulley
end
❑ Must seat on dowel
pins.
stalling sealing flange
on pulley end”,
page 47
5 - Bolt
❑ Different thread diame‐
ters ⇒ Electronic parts
catalogue
tightening sequence
⇒ page 38
6 - Seal
7 - Cylinder block
8 - Dowel pin
❑ Qty. 2
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 38

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

ing sequence
Note
Renew bolts that are tightened with turning further angle.
– Tighten bolts in stages:

1. -1 … 8- Screw in by hand as far as stop
2. -1 … 8- In diagonal sequence to 8 Nm
3. -7, 8- 20 Nm
1.3 Removing and installing poly-V belt

⇒ “1.3.1 Removing and installing poly V-belt, vehicles without air
⇒ “1.3.2 Removing and installing poly V-belt, vehicles with air
1.3.1 Removing and installing poly V-belt, ve‐

hicles without air conditioner compres‐
sor
♦ Locking pin - T10060 A-
Removing
– To slacken poly V-belt turn tensioning device in direction of
-arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
– Before removing the poly V-belt, use a piece of chalk or a felt
pen to mark the running direction.
– Remove poly V-belt.

Installing
Install in reverse order of removal, observing the following:
– 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, ve‐

hicles with air conditioner compressor
♦ Locking pin - T10060 A-
Removing
– Before removing the poly V-belt, use a piece of chalk or a felt
pen to mark the running direction.
– 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


served:
– 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
⇒ “1.4.1 Removing and installing tensioner for poly V-belt, vehi‐
cles without air conditioner compressor”, page 40
⇒ “1.4.2 Removing and installing tensioner for poly V-belt, vehi‐
cles with air conditioner compressor”, page 41
1.4.1 Removing and installing tensioner for

poly V-belt, vehicles without air condi‐
tioner compressor
Removing
– Remove poly V-belt from tensioner
⇒ “1.3.1 Removing and installing poly V-belt, vehicles without
air conditioner compressor”, page 38 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
served:
⇒ “1.3.1 Removing and installing poly V-belt, vehicles without
air conditioner compressor”, page 38 .
♦ Specified torque
⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles with‐
out air conditioner compressor”, page 34

1.4.2 Removing and installing tensioner for

poly V-belt, vehicles with air conditioner
compressor
Removing
– Remove poly V-belt from tensioner
conditioner compressor”, page 39 .
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
• Specified torque
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with
air conditioner compressor”, page 36
conditioner compressor”, page 39 .
1.5 Removing and installing vibration damp‐

er
♦ 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 adap‐
ted 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
– Set engine to “TDC for cylinder no. 1”
⇒ “2.5 Checking valve timing”, page 109 .
– 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
⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
Note

♦ All contact surfaces between bolt, vibration damper and crank‐
shaft 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- .
Further installation is carried out in reverse order of removal. Ob‐
serve the following:
1.6 Removing and installing engine support

Removing
309 .
– Unscrew bolt -arrow- for coolant pipe -1- from engine support
-2-.



– Disconnect fuel supply line -1- and line to activated charcoal

filter solenoid valve 1 - N80- -2-. Disconnect plug-in connec‐
tors ⇒ Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-
in connectors .
– Remove upper part of toothed belt guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”,
page 95 .
– Loosen bolt -1-.

– Swivel alternator -3- in -direction of arrow- towards front.
dle; do not lift.
– Unscrew bolts -arrows-.

– Remove bracket -1- from engine support -2-.
– Removing engine mounting
⇒ “2.2 Removing and installing engine mounting”, page 26 .

– Unscrew bolts -1- to -3-

Installing
served:
– Install bracket -1- to engine support -2-.

– To do this, tighten bolts -arrows- ⇒ page 45 .
Torque settings
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 253
♦ ⇒ “2.1 Assembly overview - charge air system”, page 283
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator
Component Torque setting

Bracket to engine mounting ⇒ page 45 20 Nm
1.7 Renewing crankshaft oil seal - belt pul‐

ley end
♦ Assembly tool - T10485-

♦ Extractor hook - T20143-
Procedure
– Remove toothed belt
⇒ “2.8 Removing and installing toothed belt”, page 138 .
– 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.
– Separate fitting sleeve and guide sleeve.
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Draw in seal -2- to stop using thrust piece -T10485/1- and bolt
-1- for pulley.
– Fit crankshaft sprocket onto crankshaft.

• The contact surface between vibration damper and crankshaft
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 (adjust valve timing)
1.8 Removing and installing sealing flange

on pulley end

♦ Applicator gun - VAS 6966-
♦ Scraper
♦ Sealant ⇒ Electronic Parts Catalogue
Removing
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
nected, raise and tie on right side ⇒ Heating, air conditioning;
– Remove toothed belt
NOTICE
– Unscrew bolts -1 … 8- and carefully remove sealing flange

from the glued joint.
– Drive out 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.

– 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-.
– Use applicator gut - VAS 6966- to do this.
– 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 cylinder

block.
– Tighten bolts for sealing flange ⇒ page 38 .
– Install crankshaft oil seal on belt pulley end
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 45 .

– Fit crankshaft sprocket onto crankshaft.

• The contact surface between vibration damper and crankshaft
• The machined surface -arrow- of crankshaft pulley must be
positioned over the machined surface of the crankshaft jour‐
nal.
– Install toothed belt
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
Torque settings
♦ ⇒ Fig. ““Sealing flange at belt pulley end - Prescribed torque
and tightening sequence”“ , page 38
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 51
⇒ “2.2 Removing and installing flywheel”, page 52
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 53
2.1 Assembly overview - cylinder block, gearbox end
Note
For assembly work, secure engine to engine and gearbox support

⇒ “1.3 Securing engine on engine and gearbox support”, page 16 .
1 - Bolt
❑ 60 Nm + 90°
2 - Flywheel
stalling flywheel”,
page 52
❑ Can only be fitted in one
position
3 - Engine speed sender -
G28-
stalling engine speed
sender G28 ”,
page 353
4 - Bolt
⇒ “1.1 Assembly over‐
view - ignition system”,
page 348
5 - Dowel pin
❑ Qty. 2
6 - Adapter
❑ Do not damage or bend
when assembling.
❑ Installing ⇒ page 52
7 - Bolt
tightening sequence
⇒ page 52
8 - Sealing flange with sender wheel and oil seal
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 53
2. Cylinder block, gearbox end 51

Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in stages as follows:
Stage Bolts Torque setting
2. -1 … 6- In diagonal sequence and in stages;
final torque 10 Nm
Install intermediate plate.

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.
Plug for “TDC” drilling in cylinder block at rear – specified torque
Note
♦ The plug -arrow- has an integrated seal.

♦ Renew if damaged
Bolt Torque setting

-Arrow- Tighten to 30 Nm
2.2 Removing and installing flywheel

♦ Counter-hold tool - 3067-
Removing
• Gearbox removed

– Insert counterhold - 3067- in hole on cylinder block -item B-.

– Loosen and remove flywheel bolts.
Installing
⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
51
Note

♦ Flywheel with sender wheel can only be fitted in one position.
– Insert counterhold - 3067- in hole in cylinder block -item A-.
2.3 Removing and installing sealing flange

on gearbox side
♦ Flared ring spanner tool insert AF 24 - V.A.G 1332/11-
♦ Depth gauge - VAS 6082-

♦ Locating bolt - T10340-
♦ Bolt M6x35 (3x)

Procedure
• Gearbox is removed.
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
– Remove flywheel
⇒ “2.2 Removing and installing flywheel”, page 52 .
– 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
⇒ “4.7 Setting piston to TDC position”, page 71 .
– Remove sump (bottom section)
⇒ “1.3 Removing and installing lower part of sump”,
page 197 .
– Remove upper part of sump
⇒ “1.4 Removing and installing upper part of sump”,
page 201 .
– Remove engine speed sender - G28-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 353 .

– Unscrew bolts -arrows- for sealing flange -1-.
– To press off, screw 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 56 .
♦ 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 crank‐
shaft ⇒ page 56 .

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 - Inner part
Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
face -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 with front side facing down on a clean

level surface.
– Push sealing lip support ring -1- 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 onto
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 lo‐

cating 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 re‐
mains 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 hous‐
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder 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 crankshaft
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 inserted
in threaded hole of crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool

hand-tight.
– Screw nut -B- onto threaded spindle by hand until nut 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 the nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block 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 -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
⇒ page 60 .
– If specification is achieved, proceed with subsequent work
steps ⇒ page 60 .

Re-pressing sender wheel:

– Secure assembly tool - T10134- on crankshaft flange -1-.
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly 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 nut rests
against assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange -1-.
– To guide sealing flange, screw two M6×35 mm bolts -2- into
cylinder block.
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

– Check sender wheel installation position on the crankshaft
again ⇒ page 59 .
– 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 59 .
Installing
– Tighten bolts for sealing flange ⇒ page 52 .
– Install bottom section of sump
page 197 .
– Install upper part of sump
page 201 .
– Install intermediate plate ⇒ page 52 .
– Install flywheel
⇒ “2.2 Removing and installing flywheel”, page 52 .
Torque settings
♦ ⇒ Fig. ““Sealing flange on gearbox side - specified torque and
tightening sequence”“ , page 52
♦ ⇒ Fig. ““Install intermediate plate.”“ , page 52
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
51
♦ Engine speed sender - G28-
⇒ “1.1 Assembly overview - ignition system”, page 348

3 Crankshaft
⇒ “3.1 Crankshaft dimensions”, page 61
⇒ “3.2 Renewing needle bearing in crankshaft”, page 61
⇒ “3.3 Measuring axial clearance of crankshaft”, page 64
3.1 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.
Honing dimension Conrod bearing journal diameter

mm
Basic dimension 48.00 -0.022
-0.042
3.2 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-
3. Crankshaft 61
♦ Internal puller - VAS 251 635-
♦ Drift - 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 engine
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-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
Note
The lettering on the needle bearing must be visible when installed.
– Drive in needle bearing using drift - VW 207 C- or centring

mandrel - 3176- until it is flush.
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing has been driven in too far, it must be re‐
newed because it will be damaged when it is pulled out.
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐

box; Installing gearbox .
3. Crankshaft 63
3.3 Measuring axial clearance of crankshaft

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-
♦ Dial gauge - VAS 6079-
Procedure
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder block as shown in the illustration.
– 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 measured
value.
• Axial clearance: 0.066 to 0.233 mm

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 65
⇒ “4.2 Separating new conrod”, page 67
⇒ “4.3 Removing and installing pistons”, page 67
⇒ “4.4 Removing and installing oil spray jets”, page 68
⇒ “4.5 Checking pistons and cylinder bores”, page 70
⇒ “4.6 Checking radial clearance of conrods”, page 71
⇒ “4.7 Setting piston to TDC position”, page 71
4.1 Assembly overview - pistons and conrods
1 - Bolts
❑ Oil threads and contact
surface
❑ 30 Nm + 90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure
(cracking) separating
the cap from the conrod.
❑ Mark allocation to cylin‐
der and conrod in colour
-B-.
❑ Installation position: Lug
-A- on conrod bearing
cap faces towards pul‐
ley end
3 - Bearing bushes
❑ Fitting position
⇒ page 66
❑ Renew worn bearing
shells
❑ Ensure firm seating
4 - Connecting rod
❑ With industrially
cracked conrod bearing
cap
❑ Renew as set only.
❑ Mark allocation to cylin‐
der and conrod bearing
cap in colour -B-.
❑ Measuring radial clearance ⇒ “4.6 Checking radial clearance of conrods”, page 71
❑ Separating new conrod ⇒ “4.2 Separating new conrod”, page 67 .
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end
5 - Retaining ring
❑ Qty. 2
4. Pistons and conrods 65

6 - Piston pin
❑ Removing and installing ⇒ “4.3 Removing and installing pistons”, page 67
7 - Piston
❑ Mark installation position and cylinder number ⇒ page 66 .
❑ Removing and installing ⇒ “4.3 Removing and installing pistons”, page 67
❑ Checking piston and cylinder bore ⇒ “4.5 Checking pistons and cylinder bores”, page 70
8 - Piston rings
❑ Compression rings
❑ Measuring ring gap ⇒ page 70
❑ Measuring ring-to-groove clearance ⇒ page 70
❑ 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°
9 - Piston ring
❑ Oil scraper ring
❑ Measuring ring gap ⇒ page 70
❑ Measuring ring-to-groove clearance ⇒ page 70
❑ 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
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 marking.
• Arrow on piston crown points to pulley end -arrow-.
Bearing shells - installation position

– Centre bearing shells on conrod and on conrod bearing cap.
• Distance -a- = distance -a-.

Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
4.2 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– To avoid damage, gently clamp conrod in a vice with protection
jaws, as shown in illustration.
• Clamp conrod below dashed line.
– Unscrew bolts -arrows- around 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until it is loose.
4.3 Removing and installing pistons

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

Removing
– Remove cylinder head
⇒ “1.3 Removing and installing cylinder head”, page 81 .


page 201 and detach baffle plate.
– Mark piston installation position and corresponding cylinder
number.
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 4 (page 65) .
– Remove conrod bearing cap and withdraw piston and conrod
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
served:
Note
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ page 66 .
– Install conrod bearing cap, noting installation position
⇒ Item 2 (page 65) .
– Install cylinder head
page 201 .
Torque settings
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 65
4.4 Removing and installing oil spray jets

♦ Torx bit - T10545-

Removing
sulation .
page 201 .
Note
♦ The crank web of the respective cylinder must be positioned

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

of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using Torx bit T40 -
T10545- .
– Remove oil spray jets -2-.
Installing
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
1- Pressure relief valve - 27 Nm

2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
page 201 .
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
Specified torque:
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 193
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation

4.5 Checking pistons and cylinder bores

Checking piston

♦ External micrometer 50-75 mm - VAS 6070-
– 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 not including coating (thickness 0.018 mm on
each side).
Measuring piston ring gap

– Push piston ring at right angles to cylinder wall into cylinder
bore to 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 1.0
Oil scraper ring 0.20 + 0.20 3.0
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.05 … 0.09 0.15
2nd compression ring 0.03 … 0.07 0.15
Oil scraper rings Cannot be measured

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 longitudinal di‐
rection -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 74.5 + 0.015 1)
+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.
4.6 Checking radial clearance of conrods

♦ Plastigage
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm (without turning
further angle).
– 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.
4.7 Setting piston to TDC position

Procedure
Setting piston from cylinder no. 1 to TDC position ⇒ page 71
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing ⇒ page 73
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
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 349 .

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 described.
– 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-.
sulation .

– 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 ro‐

tation only.
Setting piston from cylinder no. 1 to TDC position for repair work
on toothed belt drive and for setting valve timing
309 .
– Remove air intake pipe
⇒ “2.5 Removing and installing air intake pipe”, page 289 .
– 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
⇒ “1.4 Removing and installing connection for turbocharger”,
page 279 .
– 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-.
Vehicles without ACT:

• The asymmetrically positioned grooves on gearbox end of
both camshafts -top arrows- must now be above the horizontal
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
– If the camshafts are not positioned as described: Unscrew
locking pin - T10340- . Turn crankshaft one revolution further
until camshaft is in right position.
Vehicles with ACT:

• On exhaust camshaft, hole -arrow- in toothed belt pulley for
coolant pump must align with hole in camshaft housing.
• On inlet camshaft, grooves -arrows- must be positioned above
centre of camshaft.
A - Exhaust camshaft
E - Inlet camshaft
– If the camshafts are not positioned as described: Unscrew
locking pin - T10340- . Turn crankshaft one revolution further
until camshaft is in right position.

Plug for “TDC” drilling in cylinder block - specified torque

♦ Renew O-ring if damaged.
♦ Tighten bolt -arrow- to 30 Nm.
Torque settings
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 270
♦ ⇒ “1.1 Assembly overview - ignition system”, page 348
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
♦ ⇒ “1.2 Assembly overview - camshaft housing”, page 78

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 76
⇒ “1.2 Assembly overview - camshaft housing”, page 78
⇒ “1.3 Removing and installing cylinder head”, page 81
⇒ “1.4 Removing and installing camshaft housing”, page 85
⇒ “1.5 Checking compression”, page 88
1.1 Assembly overview - cylinder head
1 - Cylinder head gasket

❑ Renewing
stalling cylinder head”,
page 81
❑ Observe installation po‐
sition: Part number to
cylinder head
2 - Dowel sleeve
❑ Qty. 2
3 - Cylinder head
stalling cylinder head”,
page 81
❑ Check for distortion
⇒ page 77 .
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 appropri‐
ate recess.
♦ Cylinder heads without recess
do not require an oil strainer.
6 - Seal
7 - Camshaft case
❑ Removing and installing ⇒ “1.4 Removing and installing camshaft housing”, page 85
❑ The camshafts must not be removed individually.
❑ In the event of repair, the camshaft housing must be renewed completely.
8 - Bolt
76 Rep. gr.15 - Cylinder head, valve gear

9 - Bolt
❑ Sequence when loosening ⇒ page 84 .
Cylinder head - specified torque and sequence
Note

1. -1 … 10- 40 Nm
2. -1 … 10- Turn 90° further
3. -1 … 10- Turn 90° further
4. -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. Cylinder head 77
1.2 Assembly overview - camshaft housing

⇒ “1.2.1 Assembly overview - camshaft housing, vehicles with
Active Cylinder Management”, page 78
⇒ “1.2.2 Assembly overview - camshaft housing, exhaust side
with toothed belt pulley”, page 80
1.2.1 Assembly overview - camshaft housing, vehicles with Active Cylinder Man‐
agement
1 - Bolt
❑ 8 Nm
2 - Exhaust cam actuator for
cylinder 2 - N587-
stalling cam actuators”,
page 187
cylinder 3 - N595-
page 187
4 - Inlet cam actuator for cylin‐
der 3 - N591-
page 187
5 - Inlet cam actuator for cylin‐
der 2 - N583-
page 187
6 - Bolts
❑ 4 Nm
7 - Hall sender 3 - G300-
installing Hall sender 3
G300 ”, page 353
8 - Hall sender - G40-
❑ Removing and installing ⇒ “1.4.1 Removing and installing Hall sender G40 ”, page 352
9 - O-ring
❑ Check for damage, and renew if necessary; see ⇒ Electronic parts catalogue (ETKA)
10 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing
⇒ “3.2.5 Removing and installing exhaust camshaft oil seal, gearbox end, vehicles with Active Cylinder
Management”, page 153
11 - Crankshaft
❑ For coolant pump

⇒ “2.7 Removing and installing toothed belt pulley for coolant pump”, page 245
12 - Bolt
❑ Specified torque ⇒ Item 8 (page 233)
13 - Bolt
❑ 8 Nm
14 - Cap
15 - Seal
❑ Renew
16 - Dowel pin
17 - Seal
❑ Inserted into cylinder head
Note

ate recess.
18 - Seal
❑ For inlet camshaft
❑ Renewing ⇒ “3.2 Removing and installing camshaft oil seal”, page 145
19 - Seal
❑ For exhaust camshaft
20 - Camshaft case
❑ Removing and installing ⇒ “1.4 Removing and installing camshaft housing”, page 85
21 - Cap
22 - Bolt
23 - Inlet camshaft control valve 1 - N205-
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”, page 178
❑ With O-ring
❑ Check O-ring for damage.
❑ O-ring cannot be renewed individually; renew together with camshaft control valve 1 - N205- if damaged.
24 - Exhaust camshaft control valve 1 - N318-
⇒ “3.6 Removing and installing exhaust camshaft control valve 1 N318 ”, page 179
❑ With O-ring
❑ Check O-ring for damage.
❑ O-ring cannot be renewed individually; renew together with camshaft control valve 1 - N205- if damaged.
1. Cylinder head 79
Camshaft housing - specified torque and tightening sequence
Note

1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further
1.2.2 Assembly overview - camshaft housing, exhaust side with toothed belt pul‐
ley
1 - Bolt
tightening sequence
⇒ page 81
2 - Inlet camshaft control valve
1 - N205-
stalling camshaft control
valve 1 N205 ”,
page 178
❑ With O-ring
❑ Check O-ring for dam‐
age.
❑ O-ring cannot be re‐
newed individually; re‐
new together with cam‐
shaft control valve 1 -
N205- if damaged.
3 - Bolt
❑ 8 Nm
4 - Camshaft case
stalling camshaft hous‐
ing”, page 85
installing Hall sender
G40 ”, page 352
6 - Bolt
❑ 8 Nm
7 - Seal
❑ For exhaust camshaft, gearbox end
❑ Renewing
⇒ “3.2.6 Removing and installing exhaust camshaft oil seal, gearbox end; exhaust side with toothed belt
pulley on control end”, page 155

8 - Crankshaft
9 - Bolt
❑ Specified torque ⇒ Item 8 (page 233)
10 - Bolt
❑ 8 Nm
11 - Cap
12 - O-ring
13 - Seal
❑ Renew
14 - Dowel pin
15 - Seal
❑ Inserted into cylinder head
Note

ate recess.
16 - Seal
❑ For inlet camshaft
17 - Seal
❑ For exhaust camshaft (pulley end)
18 - Cap
Camshaft housing - specified torque and tightening sequence
Note

1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further
1.3 Removing and installing cylinder head

1. Cylinder head 81
♦ Bit XZN 12 - T40270-
Removing
Note
♦ Cover the opening in the gearbox with a cloth so that no fluids

can enter the gearbox housing.
♦ Fit all heat shield sleeves in the same place when installing.
♦ Cover the openings in the gearbox with a cloth to prevent any
fluid entering the clutch housing.
– Remove camshaft housing

⇒ “1.4 Removing and installing camshaft housing”,
page 85 .
– Remove intake manifold
⇒ “4.2 Removing and installing intake manifold”, page 312 .
– Release connectors and pull them off.
1- On oil pressure switch for reduced oil pressure - F378-
2- On fuel pressure sender - G247-
3- On injectors -N30- to -N33-


– Remove heat-shield sleeve.

– Separate electrical connector -arrow- on oil pressure switch -
F1- .
– Unscrew bolts -arrows- and detach oil supply pipe -1- and oil
return pipe -2-.
– Release and pull off connectors -1- and -2-.

1 - For coolant temperature sender - G62-
2 - For charge pressure positioner - V465-
– Unscrew bolt -1- from engine support.
1. Cylinder head 83
– Loosen cylinder head bolts in the sequence -1 to 10- and un‐

screw.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Installing
Note
♦ Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Ensure that no long scores or scratches are made on the sur‐
faces.
♦ Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Risk of leaks in cylinder head gasket.
♦ Carefully remove remains of emery and abrasives.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
♦ Renew self-locking nuts as well as gaskets, seals and O-rings.
♦ When installing a replacement cylinder head, the contact sur‐
faces between hydraulic compensation elements, roller rocker
fingers and cams must be oiled before installing the camshaft
housing.
♦ When cylinder head or cylinder head gasket is renewed, the
entire coolant and the engine oil must be changed.

– 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, proceed as
follows:
– Position 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 77 .
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
Continue installation in reverse order of removal. The following

should be observed:
– Install camshaft housing
⇒ “1.4 Removing and installing camshaft housing”,
page 85 .
– Install intake manifold
– Change engine oil ⇒ Maintenance ; Booklet .
– Fill cooling system with fresh coolant
Torque settings
♦ ⇒ Fig. ““Engine support - specified torque and tightening se‐
quence”“ , page 23
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 76
♦ ⇒ “4.2 Removing and installing intake manifold”, page 312
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
♦ Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Assembly overview - drive shaft .
1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump
⇒ “2.5 Removing and installing coolant pump”, page 238 .
– Remove ignition coils
page 349 .
1. Cylinder head 85
– Remove toothed belt from camshafts

⇒ “2.7 Removing toothed belt from camshaft”, page 133 .
– Disconnect electrical connector -1-.
– Detach hose clip -2- and pull off hose.
– Remove high-pressure pipe -3-
⇒ “7.3 Removing and installing high-pressure pipe”,
page 331 .
– Install connecting piece
page 279 .

– Swivel coolant lines -1- to side.
– Unscrew bolts or nuts -arrows-.

– Unclip wiring harness for lambda probe from heat shield -1-.
– Remove heat shield -1-.
– Release and pull off connector -arrow- on intake manifold

sender - GX9- .

– Release connectors and pull them off.

– The number of connectors varies.
1 - For cam actuators - N583/ N587/ N591/ N595-
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 and compensation ele‐
ments for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
Installing
Note

♦ Renew gasket and seal with oil strainer.
– Set engine to “TDC for cylinder no. 1”

NOTICE
Risk of damage to valve gear caused by axial movement of the
camshafts.
– Never move camshafts in axial direction when turning them.
– Check, if all roller rocker fingers are seated properly on valve

stem end and if their clipped into the respective compensation
element.
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.
– Fit seal with oil strainer -2- into cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
1. Cylinder head 87
– 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 ⇒ page 81 .

should be observed:
– Install high-pressure pipe
page 331 .
– Install toothed belt (adjust valve timing)
– Install ignition coils
page 349 .
– Install coolant pump
– Ensure proper connection and routing of wires ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Torque settings
♦ ⇒ “3.1 Assembly overview - valve gear”, page 144
1.5 Checking compression

♦ Spark plug socket - 3122 B-

♦ Compression tester - V.A.G 1763-
Procedure
• 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 allow it to run until the engine turns off.
– Switch off ignition.
309 .
1. Cylinder head 89
– 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 .
– Get a second mechanic to press down the accelerator pedal.
– Simultaneously operate starter until tester shows no further
pressure increase.
– 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. Specified torque 22 Nm.
– Install ignition coils with output stages
page 349 .
– Entries will have been made in the event memory of the engine
control unit because connectors were separated and the en‐
gine was started.
– Carry out the function Generate readiness code on ⇒ Ve‐
hicle diagnostic tester in Guided functions mode.

2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt cover”, page 91
⇒ “2.2 Assembly overview - toothed belt”, page 92
⇒ “2.3 Removing and installing toothed belt guard”, page 95
⇒ “2.4 Preassembling and installing valve timing tool”,
page 96
⇒ “2.5 Checking valve timing”, page 109
⇒ “2.6 Adjusting valve timing”, page 115
⇒ “2.7 Removing toothed belt from camshaft”, page 133
⇒ “2.8 Removing and installing toothed belt”, page 138
2.1 Assembly overview - toothed belt cover
1 - Lower toothed belt guard

2 - Bolt
❑ 8 Nm
3 - Engine support
tightening sequence
view - assembly mount‐
ings”, page 21
4 - Bolt
tightening sequence
view - assembly mount‐
ings”, page 21
5 - Upper toothed belt guard
6 - Bolt
❑ 8 Nm
2. Toothed belt drive 91

2.2 Assembly overview - toothed belt

⇒ “2.2.1 Assembly overview - toothed belt, exhaust side with
camshaft adjuster”, page 92
⇒ “2.2.2 Assembly overview - toothed belt, exhaust side with
toothed belt pulley”, page 94
2.2.1 Assembly overview - toothed belt, exhaust side with camshaft adjuster
1 - Toothed belt
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 138
❑ Adjusting valve timing
⇒ “2.6 Adjusting valve
timing”, page 115
2 - Bolt
❑ 25 Nm
❑ When setting the speci‐
fied torque on the torque
wrench - VAS 6583- ,
the length indicated on
the insert tool - T10500-
must be entered in the
torque wrench.
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
page 43 .
4 - Bolt
❑ 8 Nm +45°
5 - Cap
6 - Bolt Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ 50 Nm +135°
7 - Exhaust camshaft toothed belt pulley
❑ With camshaft adjuster
❑ Removing and installing camshaft adjuster
⇒ “3.3 Removing and installing camshaft adjuster”, page 157
8 - Guide bush
9 - Inlet camshaft toothed belt pulley

10 - Bolt
❑ Renew
❑ 50 Nm +135°
11 - O-ring
12 - Plug
❑ 20 Nm
❑ Renew
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
Note
Renew O-ring if damaged.
– Tighten bolt -arrow- to 30 Nm.

2.2.2 Assembly overview - toothed belt, exhaust side with toothed belt pulley
1 - Toothed belt
chalk or felt-tipped
marker pen.
❑ Check for wear ⇒ Main‐
tenance ; Booklet 3.1
stalling toothed belt”,
page 138
❑ Adjusting valve timing
⇒ “2.6.1 Adjusting valve
timing, vehicles without
ACT”, page 115
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
page 43 .
4 - Bolt
❑ Renew
❑ 50 Nm +90°
5 - Exhaust camshaft toothed
belt pulley
⇒ “2.7 Removing tooth‐
ed belt from camshaft”,
page 133
6 - Inlet camshaft toothed belt
pulley
7 - Guide bush
8 - Bolt
❑ Renew
❑ 50 Nm +135°
9 - O-ring
10 - Plug
❑ 20 Nm
❑ Renew
11 - O-ring
❑ Captive, supplied with “item 13”.
❑ Renew

12 - Spacer sleeve
❑ Supplied with item “13”.
❑ Renew
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
Note
Renew O-ring if damaged.
– Tighten bolt -arrow- to 30 Nm.
2.3 Removing and installing toothed belt

guard
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
95
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page
95
2.3.1 Removing and installing upper toothed

belt guard
Removing:
– Detach hoses from retainer -3-.
– Release clips -arrows- and remove upper toothed belt guard
-1-.
Installing:
Install in reverse order of removal. Observe the following:
Specified torques:
2.3.2 Removing and installing lower toothed

belt guard
Removing:
– Remove vibration damper
⇒ “1.5 Removing and installing vibration damper”, page 41 .


– Remove lower part of toothed belt guard.
Installing:
– Install vibration damper
⇒ “1.5 Removing and installing vibration damper”, page 41 .
Specified torques:
2.4 Preassembling and installing valve tim‐

ing tool
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”, page
96
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”,
page 99
⇒ “2.4.3 Mounting test tool VAS 611 007 without ACT”,
page 102
⇒ “2.4.4 Mounting test tool VAS 611 007 with ACT”, page 104
⇒ “2.4.5 Teaching-in test tool VAS 611 007 electronically and
performing basic setting”, page 107
2.4.1 Preassembling test tool - VAS 611 007-

without ACT
♦ Tester for checking elongation of chain links - VAS 611 007-
Procedure
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 hous‐
ing - VAS 611 007/8-
E - Adapter for angle sensor -
VAS 611 007/9- and adapter
for angle sensor - VAS 611
007/10-
❑ Adapter for angle sen‐
sor - VAS 611 007/9-
blue, for inlet camshaft
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 colour
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 posi‐
tion.
– 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 securing rings are screwed in 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 Preassembling test tool - VAS 611 007-

with ACT
♦ Adapter - VAS 611 007/14- (not illustrated)

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 hous‐
ing - VAS 611 007/8-
E - Adapter for angle sensor -
VAS 611 007/9- and adapter
for angle sensor - VAS 611
007/14-
sor - VAS 611 007/9-
blue, for inlet camshaft
sor - VAS 611 007/14-
red, for exhaust cam‐
shaft
Preassembling test tool - VAS 611 007-

– Insert angle sensor -A- colour coded red -arrow a- on red
marked side -arrow 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 -arrow b- colour coded
blue.
– Before installing the adapters for angle sensor -E- in angle
sensors -A-, check correct assignment by means of the colour
coding -a and b-.
– Insert corresponding adapter for angle sensor -E- in relevant
angle sensors -A-.

– To do this, insert adapter for angle sensor - VAS 611 007/9-

-E- in angle sensor - VAS 611 007/1- -A- with blue colour
coding -arrows a-.
• Adapters for angle sensors -E- can only be fitted in one posi‐
tion.
– Note position of dowel pins -a- when installing.

– Make sure that brake -b- is released. Do not apply force.
Note
The adapter for angle sensor - VAS 611 007/14- cannot be moun‐
ted until the angle sensor - VAS 611 007/1- is mounted in the
camshaft housing adapter - VAS 611 007/8- .
Insert adapter for angle sensor - VAS 611 007/14- -E- in angle
sensor - VAS 611 007/1- -A- with red colour coding -arrows a-.
– 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-.
– To do this, observe colour coding -arrows-.

– 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 securing rings are screwed in 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.
2.4.3 Mounting test tool - VAS 611 007- with‐

out ACT
Procedure
– Preassemble test tool - VAS 611 007-
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”,
page 96 .
– Teach-in test tool - VAS 611 007- electronically and perform
basic setting
– Turn adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/10- until display is set to ap‐
prox. 0°.
Polo 2010 LHD vehicles, Polo 2014 LHD vehicles, Polo Lim RUS
2016:
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;
Brake servo/brake master cylinder; Removing and installing
brake master cylinder .
Continued for all vehicles:
– Perform the preliminary work for checking the valve timing
– Make sure that the piston in cylinder no. 1 is at TDC position
– Make sure that brakes on angle sensor - VAS 611 007/1- are
released on both sides ⇒ page 98 .

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 cam‐
shaft 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
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– 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.
2.4.4 Mounting test tool - VAS 611 007- with

ACT
Procedure
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”, page
99 .
– Teach-in test tool - VAS 611 007- electronically and perform
basic setting
– Turn adapter for angle sensor - VAS 611 007/9- and adapter
for angle sensor - VAS 611 007/14- until display is set to ap‐
prox. 0°.

2016:
– Remove brake master cylinder ⇒ Brake system; Rep. gr. 47 ;
Brake servo/brake master cylinder; Removing and installing
brake master cylinder .
– Perform the preliminary work for checking the valve timing
Note
Before positioning the test tool - VAS 611 007- -D- against the
camshaft housing, the grooves of the camshafts must be checked
for damage.
– Align adapter for angle sensor - VAS 611 007/9- -E- by hand
to grooves of camshafts -arrows b-.
– Align adapter for angle sensor - VAS 611 007/14- -F- by hand
in hole of coolant pump toothed belt sprocket -arrow a-.
– Check position of adapter for angle sensor - VAS 611 007/9-
-E- and adapter for angle sensor - VAS 611 007/14- -F-
through inspection window and adjust if necessary by turning.

– Fit adapter for camshaft housing - VAS 611 007/8- -D- to cam‐
shaft 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
• Test tool - VAS 611 007- must rest flush against camshaft
housing.
– 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.

2.4.5 Teaching-in test tool - VAS 611 007-

electronically and performing basic set‐
ting
Procedure
– 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 illustration
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, exhaust camshaft has been taught-in.
– 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.
⇒ “2.5 Checking valve timing”, page 109
– 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

⇒ “2.5.1 Checking valve timing, vehicles without ACT”,
page 109
⇒ “2.5.2 Checking valve timing, vehicles with ACT”, page 112
2.5.1 Checking valve timing, vehicles without

ACT
Procedure
309 .
– Remove air pipe
page 279 .
– Set piston for cylinder no. 1 to TDC position
– Drain coolant
– 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-.
⇒ “2.4.1 Preassembling test tool VAS 611 007 without ACT”,
page 96 .
– Install test tool - VAS 611 007-
⇒ “2.4.3 Mounting test tool VAS 611 007 without ACT”,
page 102 .
– Make sure that brake indicator on display is green -A-.


– 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.

– Add coolant ⇒ “1.3 Draining and adding coolant”, page 225 .
2016:
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system .
Torque settings
page 232
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder


Bolt for TDC hole 30 Nm
in cylinder block
2.5.2 Checking valve timing, vehicles with

ACT
Procedure
309 .
– Remove air pipe
page 279 .
– Drain coolant
– 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-.
⇒ “2.4.2 Preassembling test tool VAS 611 007 with ACT”, page
99 .
– Install test tool - VAS 611 007-
⇒ “2.4.4 Mounting test tool VAS 611 007 with ACT”,
page 104 .
– Make sure that brake indicator on display is green -A-.



– Screw in locking pin - T10340- -A-.
– Read valve timing angles on display, and compare values with

specifications.
Specified values
-1.3° ±1.5° +0.8° ±1.5°
Note

– If necessary, adjust timing.

2016:
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system .
Torque settings
page 232
♦ ⇒ Brake system; Rep. gr. 45 ; Control unit and hydraulic unit;
Assembly overview - control unit and hydraulic unit
♦ ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder, Assembly overview - brake servo/brake master cylinder


Bolt for TDC hole 30 Nm
in cylinder block
2.6 Adjusting valve timing

⇒ “2.6.1 Adjusting valve timing, vehicles without ACT”,
page 115
⇒ “2.6.2 Adjusting valve timing, vehicles with Active Cylinder
Management”, page 124
2.6.1 Adjusting valve timing, vehicles without

ACT
♦ Engine bung set - VAS 6122-
Procedure
• Toothed belt installed.
– Check valve timing ⇒ “2.5 Checking valve timing”, page 109 .
– 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 164 .
Exhaust side with toothed belt sprocket
– Loosen toothed belt sprocket on exhaust side ⇒ page 175 .
Exhaust side with camshaft adjuster
– Loosen camshaft adjuster on exhaust side ⇒ page 170 .

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 components
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.
• Catch any engine oil which runs out immediately, and remove
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.

– Make sure that the brake indicator on the display is »red«

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

– Tighten camshaft adjuster on inlet camshaft to specified initial
torque ⇒ Fig. ““”“ , page 166 .


-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 facing
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 vehicle.

♦ 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 rev‐
olutions 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 en‐
gine 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.
NOTICE


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

-A-.
– Set the two camshafts to the determined correction angle

⇒ page 119 .
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-.


– Tighten toothed belt sprocket of exhaust camshaft to specified
initial torque ⇒ page 176 .
– Tighten camshaft adjuster of exhaust camshaft to specified
– Release brakes -a- on both sides.


-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.
Note

– Read valve timing, and compare it with specifications.
Specified angle in °
-0.5° ±1.5° +1.5° ±1.5°
– If the valve timing is not OK, adjust valve timing again.

– Unscrew locking pin - T10340- .
– Make sure that brakes on test tool - VAS 611 007- are released
on both sides.
– Tighten camshaft adjuster on inlet camshaft to specified final
final torque ⇒ page 176 .


Torque settings
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 92
page 232
2.6.2 Adjusting valve timing, vehicles with Ac‐

tive Cylinder Management
Procedure
• Toothed belt installed.
– Do not relieve tension from toothed belt, and do not remove
loosen camshaft adjuster or toothed belt sprocket.

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 components
• Catch any engine oil which runs out immediately, and remove
it.
• Remove engine oil at camshaft adjusters.

• It should still be possible to turn the camshaft adjuster and
toothed belt sprocket on the camshafts.
Setting camshafts to »0°«:



-A-.
– Set both camshafts to »0.0°«.

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.

– Make sure that the brake indicator on the display is »red«

-C-.



-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 facing
towards front, as shown in illustration.
Determining correction angle
– 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 vehicle.

♦ 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 rev‐
olutions 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.

Calculation example ACT

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 -1.3°±1.5° +0.8°±1.5°
– Set determined correction angle for camshafts.

Setting valve timing with correction angle
– Place a cloth underneath camshaft adjuster to catch any en‐
gine 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.
NOTICE


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

-A-.
– Set the two camshafts to the determined correction angle

⇒ page 119 .
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-.


– Release brakes -a- on both sides.


-A-.
– Seal camshaft adjusters -1- and -2- using suitable plugs -A-
– 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.
Note

– Read valve timing, and compare it with specifications.
Specified angle in °
-1.3° ±1.5° +0.8° ±1.5°
– If the valve timing is not OK, adjust valve timing again.

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


Torque settings
page 232
2.7 Removing toothed belt from camshaft

equipment required
♦ Torque wrench - VAS 6583-

♦ Counterhold - T10172- with adapter -T10172/1-
♦ Special wrench, 30 mm - T10499-
♦ Insert tool - T10500-

♦ Release tool - T10527-

♦ Release tool - T10527/1-
Removing
– Set piston of no. 1 cylinder to “TDC” position.
page 95 .
– Remove lower toothed belt guard
⇒ “2.3.2 Removing and installing lower toothed belt guard”,
page 95 .
– Loosen plug and securing bolt for camshaft adjuster on inlet
side
⇒ “3.3 Removing and installing camshaft adjuster”,
page 157 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
approx. one turn ⇒ page 175 .
– Loosen securing bolt of camshaft adjuster on exhaust side by
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 - T10499- .
– Remove toothed belt.

Bend radius of toothed belt
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
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



• It should just be possible to turn camshaft pulleys on cam‐
shafts but no rocking is permissible.
• Metal tab -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-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Rotate eccentric -2- of tensioning roller using special wrench,

30mm -T10499- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
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 6583- .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
– Install lower part of toothed belt guard

page 95 .
– Adjust valve timing ⇒ “2.6 Adjusting valve timing”, page 115 .
final torque. ⇒ page 172
Further assembly is carried out in the reverse order of removal.
Specified torques:
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
• ⇒ “2.2 Assembly overview - toothed belt”, page 92

• ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – specified

torque”“ , page 52
• ⇒ “1.2 Assembly overview - camshaft housing”, page 78
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
• ⇒ “1.1 Assembly overview - turbocharger”, page 270
• ⇒ “2.1 Assembly overview - charge air system”, page 283
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

equipment required


♦ Special wrench, 30 mm - T10499-


Removing
– Set piston of no. 1 cylinder to “TDC” position.
page 95 .
– Remove lower toothed belt guard
page 95 .
– Loosen plug and securing bolt for camshaft adjuster on inlet
side
⇒ “3.3 Removing and installing camshaft adjuster”,
page 157 .
– Loosen securing bolt of toothed belt pulley on exhaust side by
– Loosen securing bolt of camshaft adjuster on exhaust side by
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 - T10499- .
– Remove toothed belt.

Bend radius of toothed belt
NOTICE
Risk of damage to toothed belt by bending it excessively. The
toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
– Never bend toothed belt to a radius less than r = 25 mm.
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



• Metal tab -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-, tensioning
roller -2- and camshaft toothed belt pulleys -3- and -4-.

– Rotate eccentric -2- of tensioning roller using special wrench,

30mm -T10499- in -direction of arrow- until adjustment pointer
-3- is located approx. 10 mm to the right from adjustment win‐
dow.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting specified torque on torque wrench - VAS 6583- ,
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 6583- .
Note
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. The deviations do not affect the
toothed belt tension or the timing.
– Install lower part of toothed belt guard

page 95 .
final torque. ⇒ page 172
Further assembly is carried out in the reverse order of removal.
Specified torques:
• ⇒ “1.1 Assembly overview - poly V-belt drive”, page 34
• ⇒ “2.1 Assembly overview - toothed belt cover”, page 91
• ⇒ “2.2 Assembly overview - toothed belt”, page 92

• ⇒ Fig. ““Plug for TDC drilling in cylinder block at rear – specified

torque”“ , page 52
• ⇒ “1.2 Assembly overview - camshaft housing”, page 78
• ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
• ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
• ⇒ “1.1 Assembly overview - turbocharger”, page 270
• ⇒ “2.1 Assembly overview - charge air system”, page 283
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 144
⇒ “3.2 Removing and installing camshaft oil seal”, page 145
⇒ “3.4 Removing and installing toothed belt pulley”, page 173
⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”,
page 178
⇒ “3.6 Removing and installing exhaust camshaft control valve 1
N318 ”, page 179
⇒ “3.7 Removing and installing valve stem seals”, page 179
⇒ “3.8 Removing and installing cam actuators”, page 187
3.1 Assembly overview - valve gear
1 - Inlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 192
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 191
2 - Outlet valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 192
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 191
3 - Cylinder head
4 - Valve stem seal
❑ Renewing
stalling valve stem
seals”, page 179
5 - Valve springs
❑ Fitting position
⇒ page 145
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker fingers
stalling camshaft hous‐
ing”, page 85
❑ 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

• 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
⇒ “3.2.1 Removing and installing camshaft oil seal, for inlet cam‐
shaft on belt pulley side, exhaust side with toothed belt sprocket”,
page 145
⇒ “3.2.2 Removing and installing camshaft oil seal, for inlet cam‐
shaft on belt pulley side, exhaust side with camshaft adjuster”,
page 147
⇒ “3.2.3 Removing and installing camshaft oil seal, for exhaust
camshaft on belt pulley side, exhaust side with toothed belt
sprocket”, page 149
⇒ “3.2.4 Removing and installing camshaft oil seal, for exhaust
camshaft on belt pulley side, exhaust side with camshaft adjust‐
er”, page 151
⇒ “3.2.5 Removing and installing exhaust camshaft oil seal, gear‐
box end, vehicles with Active Cylinder Management”, page 153
⇒ “3.2.6 Removing and installing exhaust camshaft oil seal, gear‐
box end; exhaust side with toothed belt pulley on control end”,
page 155
3.2.1 Removing and installing camshaft oil

seal, for inlet camshaft on belt pulley
side, exhaust side with toothed belt
sprocket
3. Valve gear 145

♦ 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- .
– 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.
– Fit toothed belt onto camshaft sprockets (adjust valve timing)

seal, for inlet camshaft on belt pulley
side, exhaust side with camshaft adjust‐
er
3. Valve gear 147

Removing

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 pulley
side, exhaust side with toothed belt
sprocket
3. Valve gear 149

Removing

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 pulley
side, exhaust side with camshaft adjust‐
er
3. Valve gear 151

Removing
– Remove engine support
⇒ “1.6 Removing and installing engine support”, page 43 .

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
⇒ “1.6 Removing and installing engine support”, page 43 .
3.2.5 Removing and installing exhaust cam‐

shaft oil seal, gearbox end, vehicles with
Active Cylinder Management
♦ Assembly sleeve - T10505-
3. Valve gear 153

Removing
– Remove toothed belt pulley for coolant pump
⇒ “2.7 Removing and installing toothed belt pulley for coolant
pump”, page 245 .
– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out seal.
Installing
Note
– Push assembly sleeve - T10505- in direction of -arrow- into

seal -1-.
• Installation position: closed end of seal faces assembly
sleeve.
– Fit assembly sleeve - T10505- together with seal onto exhaust
camshaft -1-.
– Pin on camshaft -1- must be positioned in recess on assembly

sleeve -arrows-.

– Push seal -1- in direction of -arrow- against camshaft housing.
– Pull in oil seal onto stop using thrust piece - T10479/1- and
bolt - T10479/4- .
– Install toothed belt pulley for coolant pump
pump”, page 245 .
3.2.6 Removing and installing exhaust cam‐

shaft oil seal, gearbox end; exhaust side
with toothed belt pulley on control end
♦ Assembly tool - T10479 A-
Removing
– Remove toothed belt pulley for coolant pump
pump”, page 245 .
3. Valve gear 155

– Carefully fit extractor hook -T20143/1- between camshaft and

seal -1-.
Note
Risk of chemical damage to coolant pump seal from oil ingress

between coolant pump and cylinder head.
– Cover coolant pump with a cloth to collect any escaping oil.

– 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
grain).
Note
T10479/2- .
– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
shaft.
– 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
pump”, page 245 .
3.3 Removing and installing camshaft ad‐

juster
⇒ “3.3.1 Removing and installing inlet side camshaft adjuster, ex‐
haust side with camshaft adjuster”, page 157
⇒ “3.3.2 Removing and installing inlet side camshaft adjuster, ex‐
haust side with toothed belt sprocket”, page 163
⇒ “3.3.3 Removing and installing camshaft adjuster for exhaust
camshaft”, page 168
3.3.1 Removing and installing inlet side cam‐

shaft adjuster, exhaust side with cam‐
shaft adjuster
♦ Counter-hold tool - T10554/1-
♦ Knurled screws - T10554/2- (not illustrated)
3. Valve gear 157

♦ Counter-hold tool - T10172A-
Preparing tools
– Bolt on counter-hold tool - T10172- and counter-hold tool -
T10554/1- using knurled screws - T10554/2- -arrows-.
Procedure
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 components
– Unscrew bolts -arrows- and remove cover from camshaft ad‐

juster for exhaust camshaft.
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.
NOTICE
Risk of damage to camshaft caused by improper handling.
– Never use the camshaft clamp for counter holding.

Loosening camshaft adjuster on inlet side:

– Set piston in cylinder no. 1 to TDC position
– Fit counter-hold tool - T10554- with counter-hold tool -
T10172- 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 cam‐
shaft adjuster -1-.
– Hold camshaft in position using counterhold tool - T10554- and
counterhold tool - T10172- .
– Loosen plug -1-, and unscrew it.
3. Valve gear 159


T10172- again, to loosen securing bolt -1- of camshaft adjust‐
er.
– Loosen bolt -1- of camshaft adjuster -2-.
– Loosen securing bolt of camshaft adjuster on exhaust side
⇒ “3.3.3 Removing and installing camshaft adjuster for ex‐
haust camshaft”, page 168 .
Note
Do not relieve tension from toothed belt, and do not remove tooth‐
ed 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
camshaft adjuster -2-.
Installing
• Camshafts are located in “TDC” position.
• The camshaft pulleys are properly aligned with each other.
• Crankshaft is in “TDC position”.
Note
♦ Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.
♦ Check O-ring of plug and cap for damage, and renew if nec‐
essary; see ⇒ Electronic parts catalogue (ETKA) .

– Renew bolts -1- and -2- for both camshaft adjusters and screw
them in onto stop.
– Fit toothed belt onto camshafts ⇒ page 135 .
Tightening camshaft adjuster of inlet camshaft to specified initial
torque
Note
♦ If the camshafts are turned when pre-tightening with the crank‐

shaft 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 oc‐
cur when counter holding will be transferred to the crankshaft
via the toothed belt.
♦ The valve timing will not be affected in this case.
– Before pre-tightening, unscrew locking pin - T10340- .

– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool - T10172- .
– Pre-tighten bolt -1- to specified pre-tightening torque in two

stages.
Stage Securing bolt for camshaft Torque setting
adjuster, inlet side
1. -1- 18 Nm
2. -1- 50 Nm
– Hold exhaust camshaft in position using counterhold tool -
T10554- and counterhold tool - T10172- .

stages.
adjuster, exhaust side
1. -1- 18 Nm
2. -1- 50 Nm
Tightening camshaft adjuster to specified final torque
3. Valve gear 161

– Tighten bolt -1- for camshaft adjuster to final specified torque.

Stage Securing bolt for camshaft Angle to turn bolts
1. -1- 135°
– Tighten securing bolt for camshaft adjuster on exhaust side

-1- to final torque setting.
adjuster
1. -1- 135°
– Screw in plug -1-, and tighten it to specified torque.

Stage Plug for camshaft adjuster Torque setting
1. -1- 20 Nm
Installing
Note
Make sure to remove the camshaft clamp and the crankshaft

locking pin before cranking the engine.
Torque settings
♦ ⇒ page 52
♦ ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
♦ ⇒ “3.1 Assembly overview - valve gear”, page 144

3.3.2 Removing and installing inlet side cam‐

shaft adjuster, exhaust side with toothed
belt sprocket

3. Valve gear 163

Preparing tools
Procedure
Removing
Note


shaft adjuster.
NOTICE
Loosening camshaft adjuster on inlet side:

T10172- to camshaft pulley -1- as shown in illustration.
– The pins must be inserted properly into holes -arrows-.
shaft adjuster -1-.
– Loosen plug -1-, and unscrew it.


T10172- again, to loosen securing bolt -1- of camshaft adjust‐
er.
– Loosen bolt -1- of camshaft adjuster -2-.
– Loosen securing bolt of toothed belt pulley on exhaust side
⇒ “3.4 Removing and installing toothed belt pulley”,
page 173 .
Note
camshaft adjuster.
Removing camshaft adjuster of inlet camshaft:

– Use a cleaning cloth to remove engine oil from camshaft and
camshaft housing.
Installing
• Camshaft pulleys are properly aligned.
Note

♦ Check O-ring of plug for damage, and renew if necessary; see
⇒ Electronic parts catalogue (ETKA) .
3. Valve gear 165

– 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.
Tightening camshaft adjuster of inlet camshaft to specified initial
torque
Note



stages.
adjuster
1. -1- 18 Nm
2. -1- 50 Nm
T10172- and adapter - T10172/1- .

stages.
Stage Securing bolt for toothed Torque setting
belt pulley
1. -1- 18 Nm
2. -1- 50 Nm
Tightening camshaft adjuster of inlet camshaft to specified final
torque
– Screw locking pin - T10340- back in.


adjuster
1. -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
1. -1- 90°
3. Valve gear 167


T10172A- and counter-hold tool - T10554- .
1. -1- 20 Nm
Installing
Note

Torque settings
♦ ⇒ “3.1 Assembly overview - crankcase breather system”, page
209
- alternator
page 232
3.3.3 Removing and installing camshaft ad‐

juster for exhaust camshaft
Special tools for removing and installing the camshaft adjuster of
exhaust camshaft
♦ Support - 10 - 222 A-
♦ Shackle - 10 - 222 A /12-

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

♦ Adapter - T40091/1-
♦ Adapter - T40091/3-
♦ Adapter - T40093/3-
♦ Adapter - T40093/3-6-

3. Valve gear 169

Preparing tools
Procedure
Note

– Unscrew bolts -arrows- and remove cover from camshaft ad‐

juster for exhaust camshaft.

shaft adjuster.
NOTICE
To adjust valve timing:

Detaching camshaft adjuster on exhaust side:
– Insert counterhold - T10554- with counterhold - T10172- in

holes -arrows-.
shaft adjuster -1-.

– Hold camshaft pulley -2- in place using counterhold - T10554-

and counterhold - T10172- .
– Loosen bolt -1- one turn.
– Loosen securing bolt for camshaft adjuster on inlet side
⇒ page 164 .
Note
camshaft adjuster.
Removing camshaft adjuster of exhaust camshaft:

– Remove engine bracket.
⇒ “1.6 Removing and installing engine support”, page 43
– Detach toothed belt from camshafts
– Use a cleaning cloth to remove engine oil from camshaft and
camshaft housing.
Installing
Note

♦ Check O-ring of plug and cap for damage, and renew if nec‐
essary; see ⇒ Electronic parts catalogue (ETKA) .
3. Valve gear 171

– Renew bolts -1- and -2- for both camshaft adjusters and screw
them in onto stop.
– Adjusting valve timing
Camshaft adjuster specified final torque
Note



stages.
1. -1- 18 Nm
2. -1- 50 Nm
– Hold exhaust camshaft in position using counterhold tool -
T10554- and counterhold tool - T10172- .

stages.
adjuster, exhaust side
1. -1- 18 Nm
2. -1- 50 Nm
Tightening camshaft adjuster to specified final torque
– Screw locking pin - T10340- back in.


1. -1- 135°
– Tighten securing bolt for camshaft adjuster on exhaust side

-1- to final torque setting.
adjuster
1. -1- 135°

1. -1- 20 Nm
Installing
Note

Torque settings
- alternator

pulley
3. Valve gear 173



Preparing tools
Procedure
Removing
Note

♦ Do not relieve tension from toothed belt, and do not remove
loosen camshaft adjuster.
Loosen toothed belt pulley for exhaust camshaft

page 95 .
– Loosen bolt -1- approx. one turn using counter-hold tool -
T10172- with adapter -T10172/2- and -T10172/1- .
Remove toothed belt pulley for exhaust camshaft:
– Loosen camshaft adjuster -2- of inlet camshaft

⇒ Fig. ““Loosening camshaft adjuster on inlet side:”“ ,
page 164 .
T10172- and adapter - T10172/1- .
– Loosen bolt -1-.
⇒ “2.7 Removing toothed belt from camshaft”, page 133
– Unscrew securing bolt -1- of toothed belt pulley, and remove
toothed belt pulley.
Installing
Note

♦ Renew O-ring of plug if damaged.
3. Valve gear 175

– 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 135 .
Pre-tightening

stages.
adjuster
1. -1- 15 Nm
2. -1- 50 Nm
T10172- and adapter - T10172/1- .

stages.
Stage Securing bolt for toothed Torque setting
belt pulley
1. -1- 15 Nm
2. -1- 50 Nm
Tightening to final specified torque

adjuster
1. -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
1. -1- 90°

T10172A- and counter-hold tool - T10554- .
1. -1- 20 Nm
Installing
Further assembly is performed in the reverse order of removal.
Note

Specified torques:
•
•
•
•
3. Valve gear 177

3.5 Removing and installing camshaft con‐

trol valve 1 - N205-
⇒ “3.5.1 Removing and installing camshaft control valve 1 N205 ,
vehicles with Active Cylinder Management”, page 178
⇒ “3.5.2 Removing and installing camshaft control valve 1 N205 ,
exhaust side with toothed belt pulley”, page 178
3.5.1 Removing and installing camshaft con‐

trol valve 1 - N205- , vehicles with Active
Cylinder Management
Removing
– Release and pull off electrical connector -3-.
– 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.
Torque settings
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

1 - N205- .
Torque settings

3.6 Removing and installing exhaust cam‐

shaft control valve 1 - N318-
Removing
– Unscrew bolt -1- and remove exhaust camshaft control valve
1 - N318- .
Installing
Note

1 - N205- .
Torque settings
3.7 Removing and installing valve stem

seals
⇒ “3.7.1 Removing and installing valve stem seals (cylinder head
installed)”, page 179
⇒ “3.7.2 Removing and installing valve stem seals (cylinder head
removed)”, page 183
3.7.1 Removing and installing valve stem

seals (cylinder head installed)
♦ Spark plug socket - 3122 B-
3. Valve gear 179

♦ Removal and installation device for valve cotters - VAS 5161A-

with guide plate - VAS 5161A/32-32- .
♦ Hose adapter - VAS 5161A/35- (not shown)

♦ Valve stem seal fitting tool - 3365-
♦ Valve stem pliers - VAS 6770-
Procedure
– Remove camshaft housing
⇒ “1.4 Removing and installing camshaft housing”, page 85 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
– Unscrew spark plugs with spark plug socket - 3122 B- .


– Set piston of respective cylinder to “bottom dead centre”.
Note
♦ The pistons of cylinders no. 1 and no. 4 are at »TDC« position

after the camshaft housing has been removed.
♦ The pistons of cylinders no. 2 and no. 3 are at »bottom dead
centre« position after the camshaft housing has been re‐
moved.
♦ Crank engine via crankshaft half a turn in direction of engine
rotation. The pistons for cylinders no. 1 and no. 4 are at »bot‐
tom dead centre« position.
♦ When cranking the engine, hold and guide the toothed belt by
hand to prevent it from being damaged.
– Fit guide plate -VAS 5161A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Screw hose adapter - VAS 5161A/35- into respective spark
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/32-2- onto assembly cartridge and
insert cartridge into guide plate -VAS 5161A/32-3- .
– 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.
3. Valve gear 181

– 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-.

– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
– Insert valve spring and valve spring plate. For installation po‐
sition of valve spring refer to ⇒ page 145 .
If valve cotters have been removed from assembly cartridge:

– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until 3 grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Release the spring washer. The spring force pushes the wash‐
er back upwards and holds the valve cotters in place.
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
device from above, and pick up valve cotters.
– To do this, move knurled screw back and forth to press apart
valve cotters and capture them in assembly cartridge.

– Bolt guide plate -VAS 5161A/32-1- 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 spark plugs ⇒ Maintenance ; Booklet .
– Install camshaft housing
⇒ “1.4 Removing and installing camshaft housing”, page 85 .
Torque settings
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Assembly overview - drive shaft
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-
3. Valve gear 183

♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem pliers - VAS 6770-
♦ Valve stem seal fitting tool - 3365-
Procedure
– Remove cylinder head
– Insert cylinder head tensioning device - VAS 6419- into engine
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 cham‐
ber 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 secure
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.
3. Valve gear 185

– Lightly oil sealing lip of valve stem seal -A-.

– Carefully press valve stem oil seal -A- onto valve guide using
valve stem seal fitting tool - 3365- .
– Insert valve spring and valve spring plate. For installation po‐
sition of valve spring refer to ⇒ page 145 .
If valve cotters have been removed from assembly cartridge:

– First, insert valve cotters into insertion device - VAS 5161 A/
32-3- .
– Press down spring washer until 3 grooves are visible.
– Fit valve cotters into grooves.
• Larger diameter of valve cotters faces upwards.
– Release the spring washer. The spring force pushes the wash‐
er back upwards and holds the valve cotters in place.
– Press assembly cartridge - VAS 5161A/32-1- onto insertion
device from above, and pick up valve cotters.
– To do this, move knurled screw back and forth to press apart
valve cotters and capture them in assembly cartridge.
– 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

3.8 Removing and installing cam actuators

⇒ “3.8.1 Removing and installing exhaust cam actuator for cylin‐
der 2 N587 ”, page 187
⇒ “3.8.2 Removing and installing exhaust cam actuator for cylin‐
der 3 N595 ”, page 188
⇒ “3.8.3 Removing and installing inlet cam actuator for cylinder 2
N583 ”, page 189
⇒ “3.8.4 Removing and installing inlet cam actuator for cylinder 3
N591 ”, page 190
3.8.1 Removing and installing exhaust cam

actuator for cylinder 2 - N587-
Overview of fitting locations - cam actuator
1 - Exhaust cam actuator for cylinder 2 - N587-
3 - Inlet cam actuator for cylinder 2 - N583-
Removing
309 .
– Disconnect relevant electrical connector -1-.

– Remove bolts -arrows- and detach cam actuator.
Installing
Note
Check O-ring for damage. If O-rings are damaged, renew cam

actuator.
– Check pins of cam actuators for damage.

• The pins must not be bent or worn.
• If cam actuator is damaged, camshaft housing must be re‐
newed.
– Bring pins of actuators for cam actuator into installation posi‐

tion.
Pins of the actuators must be inserted completely -arrows-.
Torque settings
♦ Assembly overview - valve gear
♦ Assembly overview - turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 270
3. Valve gear 187

3.8.2 Removing and installing exhaust cam

actuator for cylinder 3 - N595-
Removing
309 .

charcoal filter.
Note


– Remove bolts -arrows- and press crankcase breather hose
slightly to one side.

Installing
Note

actuator.

newed.

tion.
Torque settings

3.8.3 Removing and installing inlet cam ac‐

tuator for cylinder 2 - N583-
Removing
309 .

Installing
Note

actuator.

newed.

tion.
Torque settings
3. Valve gear 189

3.8.4 Removing and installing inlet cam ac‐

tuator for cylinder 3 - N591-
Removing
309 .

Installing
Note

actuator.

newed.

tion.
Torque settings

4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 191
⇒ “4.2 Checking valves”, page 191
⇒ “4.3 Valve dimensions”, page 192
4.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– 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. Inlet and exhaust valves 191

4.3 Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
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

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 193
⇒ “1.2 Engine oil:”, page 196
⇒ “1.3 Removing and installing lower part of sump”, page 197
⇒ “1.4 Removing and installing upper part of sump”, page 201
⇒ “1.5 Removing and installing oil pump”, page 204
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 205
1.1 Assembly overview - sump/oil pump
Note
♦ Large quantities of swarf or metal particles found when performing repairs to the engine 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.
♦ Oil spray jet and pressure relief valve ⇒ page 67 .
1. Sump, oil pump 193

1 - Nut
❑ 9 Nm
2 - Oil level and oil temperature
sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 205
3 - Seal
4 - Oil drain plug
❑ Renew
Note
♦ The oil drain plug only has to be

replaced if it has a permanent
seal.
♦ Always renew oil seal.
❑ 30 Nm
5 - Seal
6 - Lower part of sump
stalling lower part of
sump”, page 197
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 ⇒ “1.4 Removing and installing upper part of sump”, page 201
13 - Baffle plate
14 - Sprocket
❑ For oil pump drive.
15 - Dowel pin
16 - Oil filters
❑ Remove and install with oil filter tool - 3417-
❑ Before installing, lightly coat seal with clean engine oil.
194 Rep. gr.17 - Lubrication

❑ If threaded connection for oil filter in top section of sump is loosened
⇒ Fig. ““Tightening connecting union for oil filter”“ , page 195
❑ 20 Nm
17 - Seal
18 - Oil pump
❑ Removing and installing ⇒ “1.5 Removing and installing oil pump”, page 204
19 - Bolt
❑ 10 Nm
20 - O-ring
21 - Oil intake tube
❑ Clean strainer if soiled
22 - Bolt
❑ Tightening sequence ⇒ page 195
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 nuts - 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.
Torque setting
Connecting union Torque setting
-2- 50 Nm
Lower part of sump - specified torque and tightening sequence

2. -1 … 19- 12 Nm

Upper part of sump - specified torque and tightening sequence
Note

1. -1 … 19- 8 Nm
2. -1 … 19- Turn 90° further
1.2 Engine oil:

Engine oil capacity
The oil capacity is 4.0 l including oil filter.
For oil capacities, oil specifications and viscosity grades, refer to
⇒ Maintenance tables .

1.3 Removing and installing lower part of

sump
Special tools and work‐
shop equipment re‐
quired
♦ Wedge - T10383/2-
♦ Cutting tool - T10561-
♦ Applicator gun - VAS

6966-

♦ Protective mat - VAS

531003-
♦ Scraper
♦ Sealant remover
♦ Hand drill with plastic
brush
♦ Safety glasses
♦ Commercially availa‐
ble scraper
♦ Sealant ⇒ Electronic
Parts Catalogue
Cutting tool - T10561-
1- Bolt
2- Washer
3- Bracket
4- Knife
5- Guide
6- Handle
7- Inserts for support
(rod) for conver‐
sion of handle
8- Bolt
9- Support bearing
Removing
– Drain engine oil.
– Remove noise insula‐
tion ⇒ General body
repairs, exterior; Rep.
gr. 66 ; Noise insula‐
tion; Assembly over‐
view - noise insula‐
tion .
– If necessary, remove
front right wheel
housing liner ⇒ Gen‐
eral body repairs, ex‐
terior; Rep. gr. 66 ;
Wheel housing liner;
Assembly overview -
front wheel housing
liner .
– If necessary, remove
radiator cowl
⇒ “4 Radiator, radia‐
tor fan”, page 257 .

– After radiator cowl has been removed, fit protective mat - VAS
531003- to vehicle as shown in illustration.
– Disconnect electrical connector -1- on oil level and oil temper‐

ature sender - G266- .
– 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 cant‐
ing.

– 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 bon‐
ded joint in the same way.
– Carefully detach lower part of sump from adhesive bond using
a commercially available scraper.
– Carefully lever off lower part of sump using a suitable assem‐

bly lever or screwdriver at position marked with an -arrow-.
Installing
⇒ Fig. ““Lower part of sump - specified torque and tightening
sequence”“ , page 195
– Cover open parts of engine so that lubrication system does not
become contaminated.
– Spray sealing surface with sealant remover and leave to act.
– Remove sealant residues from sump upper part with a flat
scraper.
– Remove sealant residue from sump (bottom section) using a

rotating plastic brush, for example.
CAUTION
Risk of eye injury caused by sealant residue.

– Observe use-by date of sealant.

2 mm).

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

bottom section of sump using applicator gun - VAS 6966- .
– Do not make sealant bead thicker than specified.
• Thickness of sealant bead: 2 to 3 mm.
• Apply sealant bead as shown.
– Run bead along inner side of bolt holes -arrows-.

– Take particular care when applying sealant bead in area of the
sealing flange.
Note
♦ The lower sump section must be installed within 5 minutes of

the sealant being applied.
♦ Allow sealant to cure for approx. 30 minutes after installing
lower part of sump. Only then fill with engine oil.
– Position bottom section of sump and tighten bolts

⇒ page 195 .
– Replenish engine oil, and check oil level ⇒ Maintenance ;
Booklet .
1.4 Removing and installing upper part of

sump

♦ Hand drill with plastic brush

♦ Safety glasses
Removing
– Remove air conditioner compressor from bracket and tie it up
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing and installing air conditioner compressor .
page 197 .
– Remove oil pump
⇒ “1.5 Removing and installing oil pump”, page 204 .
– Unscrew securing bolts -arrows- for gearbox to upper section

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.
♦ Risk of blockage in lubrication system from excess sealant.

– 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.

2 mm).

– Apply sealant bead -arrow- to clean sealing surface of sump

(top section) with applicator gun - VAS 6966- .
Note
Risk of blockage in lubrication system from excess sealant.

– Apply sealant bead -arrow- onto clean sealing surface of upper
part of sump as shown in illustration.
• Thickness of sealant bead: 2 to 3 mm.
Note
The top section of the sump must be installed within 5 minutes of

the sealant being 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 196 .
should be observed:
– Install oil pump
Booklet .
Torque settings
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Installing gearbox
1.5 Removing and installing oil pump

Removing
page 197 .
– 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
page 197 .
Booklet .
Torque settings
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 sender
- G266- -item 4-.
Installing
Note
Renew oil seal -2-.

Booklet .
Torque settings

2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 207
⇒ “2.2 Removing and installing engine oil cooler”, page 207
2.1 Assembly overview - engine oil cooler
1 - Engine oil cooler

❑ Observe notes
⇒ “1 Sump, oil pump”,
page 193
stalling engine oil cool‐
er”, page 207
❑ Renew coolant after re‐
placing
2 - Bolt
❑ 8 Nm + 90°
3 - Oil seals
2.2 Removing and installing engine oil cool‐

er
Removing
– Drain coolant
Note
Do not reuse coolant which has been drained off.

2. Engine oil cooler 207

– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
served:
– Insert new O-rings.
Torque settings
♦ ⇒ “2.1 Assembly overview - engine oil cooler”, page 207

3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 209
⇒ “3.2 Removing and installing oil separator”, page 210
3.1 Assembly overview - crankcase breather system
1 - Hose
❑ For crankcase ventila‐
tion.
2 - Cover
❑ For oil separator
3 - Oil separator
stalling oil separator”,
page 210
❑ Renew if damaged
4 - O-ring
5 - Union
6 - Hose
tion.
7 - Bolt
❑ Self-locking
❑ 9 Nm
Oil separator - specified torque and sequence

– Tighten bolts in the sequence -1 … 9- to 9 Nm.
3. Crankcase ventilation 209

3.2 Removing and installing oil separator

♦ Scraper
♦ Commercially available studs, M6x20 mm, qty. 2
♦ Sealant remover
Removing
– 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
served:
– Cover open parts of engine so that lubrication system does not
become contaminated.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Screw 2 M6x20 mm studs a few turns into holes -arrows-.

2.0 mm).
– Apply bead of sealant -arrow- onto clean sealing surface of oil

separator using applicator gun - VAS 6966- as illustrated.
Note
Danger of blocking lubrication system with excess sealant.

– Apply bead of sealant -arrow- onto clean sealing surface of oil
separator as shown in illustration.
• Width of sealant bead: 2.0 mm.
The oil separator must be installed within 5 minutes of sealant
being applied.
3. Crankcase ventilation 211

– Fit oil separator onto studs -arrows- and push onto crankcase.
– Start securing bolts.
– Unscrew studs.
– Oil separator – specified torque and tightening sequence
⇒ page 209 .
Further installation is carried out in reverse order of removal. Ob‐
serve the following:
Torque settings
♦ ⇒ Fig. ““Oil separator - specified torque and sequence”“ , page
209
♦ ⇒ “2.2 Assembly overview - electric coolant pump”,
page 234

4 Oil filter, oil pressure switch

⇒ “4.1 Assembly overview - oil filter/oil pressure switch”,
page 213
⇒ “4.2 Removing and installing oil pressure switch F1 ”,
page 214
⇒ “4.3 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 215
⇒ “4.4 Checking oil pressure”, page 216
⇒ “4.5 Removing and installing oil pressure regulating valve N428
”, page 218
4.1 Assembly overview - oil filter/oil pressure switch
1 - Oil filters
❑ Remove and install with
oil filter tool - 3417-
❑ Before installing, lightly
coat seal with clean en‐
gine oil.
❑ If threaded connection
for oil filter in top section
of sump is loosened
⇒ Fig. ““Tightening con‐
necting union for oil fil‐
ter”“ , page 195
❑ 20 Nm
❑ Observe notes
⇒ page 193
2 - Oil pressure switch for re‐
duced oil pressure - F378-
❑ Switch pressure 0.3 to
0.6 bar
❑ Checking
⇒ “4.4 Checking oil
pressure”, page 216
stalling oil pressure
switch for reduced oil
pressure F378 ”,
page 215
❑ 20 Nm
3 - Seal
❑ Renew O-ring after
each removal
4 - O-ring
5 - Valve for oil pressure control - N428-
⇒ “4.5 Removing and installing oil pressure regulating valve N428 ”, page 218
6 - Bolt
❑ 8 Nm
4. Oil filter, oil pressure switch 213

7 - Seal
❑ Renew O-ring after each removal
8 - Oil pressure switch - F1-
❑ Switch pressure 2.15 to 2.95 bar
❑ Checking ⇒ “4.4 Checking oil pressure”, page 216
❑ Removing and installing ⇒ “4.2 Removing and installing oil pressure switch F1 ”, page 214
❑ 20 Nm
4.2 Removing and installing oil pressure

switch - F1-
♦ Jointed wrench 24 mm - T40175-
Removing
Note
Fit all heat shield sleeves in the same place when installing.


– Separate electrical connector -arrow-.

– Place a cloth underneath to catch escaping engine oil.
– Remove oil pressure switch - F1- .
Installing
served:
Note
Screw oil pressure switch - F1- immediately into bore to avoid loss
of oil.
– Cut open the captive seal to renew it.

– Check oil level ⇒ Maintenance ; Booklet .
Torque settings
♦ ⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page
213

switch for reduced oil pressure - F378-
♦ Jointed wrench 24 mm - T40175-
Removing
– Pull activated charcoal filter solenoid valve 1 - N80- -3- off in‐
take manifold and push it downwards slightly.


– Unscrew oil pressure switch for reduced oil pressure - F378-
-1-.
Installing
⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page
213
Note
Insert new oil pressure switch for reduced oil pressure - F378-
immediately in bore to avoid loss of oil.
– Cut open the captive seal to renew it.

– Check oil level ⇒ Maintenance ; Booklet .
Torque settings
213
4.4 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
Procedure
• 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-
⇒ “4.2 Removing and installing oil pressure switch F1 ”, page
214 .
– 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 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 219 .
– Start engine.
– Increase engine revs to 3800 rpm and read off oil pressure on
the 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 219 .
– Interrogate the engine control unit event memory and delete
all event entries ⇒ Vehicle diagnostic tester.
– Check oil pressure control valve - N428- ⇒ 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
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- using
test leads from auxiliary measuring 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, otherwise
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 test leads from aux‐
iliary measuring 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 219 .
– 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 219 .
– Install oil pressure switch for reduced oil pressure - F378-
⇒ “4.3 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 215 .
– Interrogate the engine control unit event memory and delete
all event entries ⇒ Vehicle diagnostic tester.
Torque settings
213

regulating valve - N428-
Removing
Note
Fit all heat shield sleeves in the same place when installing.

– Detach heat insulation sleeves.


– Unscrew bolt -2- and pull off valve for oil pressure control -
N428- .
Installing
⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page
213
Note
Renew O-ring.


19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 220
⇒ “1.2 Checking cooling system for leaks”, page 223
⇒ “1.3 Draining and adding coolant”, page 225
1.1 Connection diagram - coolant hoses
Note
♦ The arrows point in the direction of coolant flow.

♦ The arrow markings on coolant pipes and on ends of coolant hoses must align.
Vehicles ►June 2013
1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 225
3 - Cylinder head/cylinder
block
placing
❑ Assembly overview
view - cylinder head”,
page 76
4 - Exhaust turbocharger
view - turbocharger”,
page 270
stalling turbocharger”,
page 274
5 - Integrated exhaust manifold
6 - Heat exchanger for heater
placing
7 - Radiator outlet coolant -
G62-
view - coolant tempera‐
ture sender”, page 236
⇒ “2.8 Removing and installing coolant temperature sender G62 ”, page 248
220 Rep. gr.19 - Cooling

8 - Coolant pump
❑ With thermostat housing
❑ Assembly overview ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 232
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 238
❑ Removing and installing thermostat ⇒ “2.6 Removing and installing thermostat”, page 242 .
❑ Assembly overview ⇒ “2.1 Assembly overview - engine oil cooler”, page 207
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 207
10 - Radiator outlet coolant temperature sender - G83-
❑ Assembly overview ⇒ “2.3 Assembly overview - coolant temperature sender”, page 236
⇒ “2.9 Removing and installing radiator outlet coolant temperature sender G83 ”, page 250
11 - Radiator for engine coolant
❑ Renew coolant after replacing
❑ Assembly overview ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 257
❑ Removing and installing ⇒ “4.3 Removing and installing radiator”, page 260
12 - Charge air cooling pump - V188-
❑ Assembly overview ⇒ “2.2 Assembly overview - electric coolant pump”, page 234
13 - Radiator for charge air cooling circuit
14 - Charge air cooler in intake manifold
❑ Assembly overview ⇒ “2.1 Assembly overview - charge air system”, page 283
❑ Removing and installing ⇒ “2.2 Removing and installing charge air cooler”, page 285
Vehicles, June 2013 ►
1. Cooling system/coolant 221

1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 225
3 - Cylinder head/cylinder
block
placing
view - cylinder head”,
page 76
view - turbocharger”,
page 270
page 274
5 - Integrated exhaust manifold
6 - Heat exchanger for heater
placing
G62-
⇒ “2.8 Removing and installing coolant temperature sender G62 ”, page 248
8 - Coolant pump
❑ With thermostat housing
❑ Assembly overview ⇒ “2.1 Assembly overview - coolant pump, thermostat”, page 232
❑ Removing and installing ⇒ “2.5 Removing and installing coolant pump”, page 238
❑ Removing and installing thermostat ⇒ “2.6 Removing and installing thermostat”, page 242 .
❑ Assembly overview ⇒ “2.1 Assembly overview - engine oil cooler”, page 207
❑ Removing and installing ⇒ “2.2 Removing and installing engine oil cooler”, page 207
❑ Assembly overview ⇒ “2.3 Assembly overview - coolant temperature sender”, page 236
11 - Radiator for engine coolant

13 - Radiator for charge air cooling circuit
⇒ “4.4 Removing and installing water radiator for charge air cooling circuit”, page 263
14 - Charge air cooler in intake manifold
1.2 Checking cooling system for leaks

equipment required
♦ Adapter for cooling system tester - V.A.G 1274/8-

♦ Cooling system tester - V.A.G 1274 B-

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

• Engine at operating temperature.

– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- on coolant expansion tank.
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate and rectify
leaks.
Note
The pressure drop of 0.2 bar within 10 minutes depends on the

how far the coolant can cool down. The colder the engine, the
lower the pressure drop. If necessary, repeat the check while the
engine is cold.
– If this pressure is not maintained, locate and rectify leaks.
Checking pressure relief valve in filler cap:

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- to filler cap -1-.
– Build up pressure using hand pump of cooling system tester.
♦ The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
1.3 Draining and adding coolant


equipment required

♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Refractometer - T10007 A-
♦ Safety glasses
♦ Safety gloves

Draining
CAUTION

– Place drip tray for workshop hoist - VAS 6208- underneath.
Draining coolant from radiator:

– Open spring-type clip -arrow- and pull coolant hose off.
Draining coolant from radiator for charge air cooling circuit:

– Open spring-type clip -arrow-.
– Pull coolant hose off water radiator for charge air cooling cir‐
cuit.
Note
Filling

Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds 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 hose on bottom left to radiator.

– Secure coolant hose with spring-type clip -arrow-.
– Connect coolant hose to water radiator for charge air cooling

circuit.
– Secure coolant hose with spring-type clip -arrow-.
– 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, which
is collected.
– 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 system
to below atmospheric pressure.
• The needle on the gauge should move into the green zone.
– Also, open valve -A- briefly.
– To do this, turn lever in direction of flow so that hose of spare
container for cooling system charge unit - VAS 6096/1- is filled
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 proc‐
ess.
♦ 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 draws coolant from the
spare container for cooling system charge unit - VAS 6096/1- ,
thus filling the cooling system.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.

– Fill coolant up to max. marking -arrow- on coolant expansion

tank -1-.
– 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.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Run engine at idling speed until the coolant hoses on the ra‐
diator are heated up.
– Switch off engine and let it cool off.
– Check coolant level in coolant expansion tank -1-.

• When the engine is cold, the coolant level must be between
the min. and the max. markings.
• When the engine is at operating temperature, it is permissible
that the coolant level is at the "max." mark -arrow-.
– Fill more coolant if necessary.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 232
⇒ “2.2 Assembly overview - electric coolant pump”, page 234
⇒ “2.3 Assembly overview - coolant temperature sender”,
page 236
⇒ “2.4 Removing and installing electric coolant pump”,
page 236
⇒ “2.5 Removing and installing coolant pump”, page 238
⇒ “2.6 Removing and installing thermostat”, page 242
pump”, page 245
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 248
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 250
2.1 Assembly overview - coolant pump, thermostat
1 - Thermostat housing
stalling thermostat”,
page 242
2 - Thermostat
❑ For cylinder block cool‐
ant circuit
❑ Different versions. Re‐
fer to ⇒ Electronic parts
catalogue .
❑ Up to 07.2016: Starts to
open at approx. 105 °C
❑ From 07.2016 onwards:
Starts to open at approx.
97 °C
installing thermostat for
cylinder block coolant
circuit”, page 244
3 - Seal
4 - Coolant pump
stalling coolant pump”,
page 238
❑ Renew toothed belt as
well when renewing
coolant pump
5 - Bolt
❑ 8 Nm

❑ Thread-forming
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque
6 - Seal
7 - Toothed belt guard
❑ For toothed belt for coolant pump
8 - Bolt
❑ 20 Nm + 90°
9 - O-ring
10 - Toothed belt
❑ Renew toothed belt after removal
11 - Crankshaft
12 - Bolt
❑ 8 Nm
13 - Bolt
❑ 8 Nm
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to torque.
14 - Cover
❑ For thermostat
15 - Seal
16 - 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
⇒ “2.6.1 Removing and installing thermostat for main coolant circuit (radiator)”, page 242
❑ Fitting position ⇒ Fig. ““Installation position of thermostat for cylinder head coolant circuit”“ , page 234
17 - Bolt
2. Coolant pump, regulation of cooling system 233

Installation position of thermostat for cylinder head coolant circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.
Thermostat housing to coolant pump - specified torque and tight‐

ening sequence
– Screw bolts in loosely.
– Tighten bolts in the sequence shown.
Tightening sequence Torque setting
-A- 8 Nm
-B- 8 Nm
-C- 8 Nm
-D- 8 Nm
-E- 8 Nm
-F- 8 Nm
Cover for thermostat to thermostat housing - specified torque and

tightening sequence
– Screw in bolts for cover -1- loosely.
– Tighten bolts for cover -1- in the sequence shown.
Tightening sequence Torque setting
-A- 8 Nm
-B- 8 Nm
-C- 8 Nm
-D- 8 Nm
2.2 Assembly overview - electric coolant pump

1 - Charge air cooling pump -

V188-
❑ with holder
2 - Coolant hose
3 - Bolt
❑ 8 Nm
4 - Coolant hose

2.3 Assembly overview - coolant temperature sender
1 - Radiator outlet coolant tem‐

perature sender - G83-
❑ 35 Nm
stalling radiator outlet
coolant temperature
sender G83 ”,
page 250
2 - O-ring
3 - O-ring
G62-
stalling coolant temper‐
ature sender G62 ”,
page 248
5 - Bolt
❑ 8 Nm
2.4 Removing and installing electric coolant

pump
♦ Hose clamps to 25 mm - 3094-

Removing
CAUTION



– 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
served:
Note
Secure all hose connections with hose clips corresponding to the

series equipment ⇒ Electronic Parts Catalogue .

– Check coolant level ⇒ page 231 .
Torque settings
page 234
2.5 Removing and installing coolant pump


equipment required
♦ Coolant system charge unit - VAS 6096-


Removing
– Drain coolant
Note
♦ Do not reuse coolant which has been drained off.

♦ Cover the opening in the gearbox with a cloth so that no fluids
can enter the gearbox housing.
♦ Cover the openings in the gearbox with a cloth to prevent any
fluid entering the clutch housing.

309 .
– Remove air pipe
charcoal filter.
Note


– 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.
– Unclip wiring harness -arrows-.

– Move coolant hose on retainer -2- clear to one side.

– Release hose clips -arrows- and detach coolant hoses.

– Detach coolant pump with toothed belt.
Installing
should be observed:
Note
♦ Renew gasket for housing -arrows-.

♦ Renew the toothed belt of the coolant pump.
♦ Secure hose connections with hose clips according to pro‐
duction standard ⇒ Electronic parts catalogue .
– Ensure proper seating of gaskets -arrows-.

– Lubricate seal for coolant pump lightly with coolant.
Note
♦ 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.
– Set No. 1 cylinder to TDC

– Fit toothed belt so that it is centred and move coolant pump
into installation position.
– Mount coolant pump on cylinder head with securing bolts.

Tightening sequence
2. -1 … 5- 10 Nm
– Loosen all bolts again by one turn.
– Apply torque wrench -VAS 6583- with hexagon key (10 mm)
-item 6- to coolant pump.
Note
For ease of handling, apply torque wrench -VAS 6583- vertically.
– Have a second mechanic apply a torque of 30 Nm to coolant

pump.
Note
♦ Do not support torque wrench with your other hand.

♦ Do not apply »excessive force« to torque wrench.
– While keeping coolant pump under tension, tighten bolts for

coolant pump in specified sequence:
3. -2, 1, 5- 10 Nm
4. -3, 4, 5, 1, 2- 12 Nm
Torque settings
♦ Tightening sequence ⇒ page 242
page 232
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Exploded view -
battery
♦ Crankcase breather hose ⇒ Item 11 (page 273) .
2.6 Removing and installing thermostat

⇒ “2.6.1 Removing and installing thermostat for main coolant cir‐
cuit (radiator)”, page 242
⇒ “2.6.2 Removing and installing thermostat for cylinder block
coolant circuit”, page 244
2.6.1 Removing and installing thermostat for

main coolant circuit (radiator)

♦ Special wrench - T10508-

Removing
– Drain coolant
Note
– Remove air pipe

– 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
served:
– 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.

Torque settings
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - specified
torque and tightening sequence”“ , page 234
2.6.2 Removing and installing thermostat for

cylinder block coolant circuit
Removing

– Unscrew bolts in the sequence -F to A-.

– Detach coolant pump from thermostat housing.
– Detach thermostat -2- from coolant pump -1-.

Installing
served:
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 234 .
Torque settings
♦ ⇒ Fig. ““Thermostat housing to coolant pump - specified torque
and tightening sequence”“ , page 234

pulley for coolant pump

♦ Removal tool - T10498-
♦ Assembly sleeve - T10505-
♦ Puller - 3032-
♦ Adapter - 3032/1-2- (not illustrated)

Removing
– Unscrew bolt -1- using counterhold - T10172- with adapter -
T10172/2- .
– Screw in bolt -1- by 3 turns.

– Tighten bolt -1- for adapter - 3032/2- while it is positioned in

the centre of the elongated hole.
– Fit puller - 3032- on toothed belt pulley -1- as shown in illus‐
tration.
– Push adapter - 3032/1- to stop in -direction of arrow-.

– Tighten bolt -2- hand-tight.
– Turn bolt -3- in direction of -arrow- until toothed belt pulley has
been pulled off.
Note
After the toothed belt pulley has been removed, renew the O-ring
on the camshaft.
Removing O-ring
The O-ring -1- must be fitted at a depth of approx. 15 mm onto

camshaft journal.
– Guide assembly tool - T10498- above camshaft as far as O-
ring.
– Turn assembly tool - T10498- to bring point of tool under O-

ring - -see illustration-.
– Pull O-ring off camshaft towards front.
Installing O-ring

– Fit new O-ring -1- onto stub of camshaft.
Note
Pin on camshaft must be positioned in recess on assembly sleeve

- T10505- .
– Fit assembly sleeve - T10505- onto camshaft and push it to

stop by hand in -direction of arrow-.
– Pull off assembly sleeve - T10505- .
O-ring must be positioned in groove on camshaft.
Installing
Note
♦ Do not use any impact tools!

♦ Push the toothed belt pulley onto the camshaft only by hand.
♦ This prevents the camshaft from being moved in axial direc‐
tion.
Fit toothed belt pulley:
– Fit toothed belt pulley -1- onto camshaft -2- so that the dowel
pin of camshaft is seated in the hole of toothed belt pulley
-arrows-.
Torque settings
page 232
2.8 Removing and installing coolant temper‐

ature sender - G62-

Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-1- on coolant expansion tank -2- briefly and then close cap
again (it should click into place).
CAUTION


– Disconnect electrical connectors.
Note
Place a cloth underneath to catch escaping coolant.
– Unscrew bolt -1- and pull off coolant temperature sender -

G62- -item 2-.
Note
♦ 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.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head in order to avoid loss of coolant.
Installing
served:
Note
Renew O-ring.

Torque settings
♦ ⇒ “2.3 Assembly overview - coolant temperature sender”,
page 236
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-

♦ Socket AF 29 - VAS 262 003-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-1- on coolant expansion tank -2- briefly and then close cap
again (it should click into place).
CAUTION


– Release and disconnect electrical connector -2- from radiator

outlet coolant temperature sender - G83- -1-.
– Place a cloth underneath to catch escaping coolant.
– Unscrew radiator outlet coolant temperature sender - G83-
-1- from radiator -3-.
– Unscrew radiator outlet coolant temperature sender - G83-
using socket AF 29 - VAS 262 003- .
Installing
served:
Note
♦ Check O-ring for damage, and renew if necessary; see ⇒

Electronic parts catalogue (ETKA) .
♦ Insert new coolant temperature sender - G62- immediately in‐
to connection in order to avoid loss of coolant.
– Install noise insulation at front ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Noise insulation .
Torque settings
♦ ⇒ “2.3 Assembly overview - coolant temperature sender”,
page 236

3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 253
⇒ “3.2 Removing and installing coolant pipes”, page 253
3.1 Assembly overview - coolant pipes
1 - Coolant hose
2 - Coolant pipe
❑ Clipped onto intake
manifold (bottom)
❑ To remove, remove in‐
take manifold
stalling intake manifold”,
page 312
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

3. Coolant pipes 253

Removing
CAUTION
– Clamp off coolant hoses on coolant pipe using hose clamps

up to 25 mm - 3094- .
– Release hose clips -arrows- and detach coolant hoses.

– Lay intake manifold -1- on the workbench as shown.

– Push wooden block -2- under intake manifold.
Note
To avoid damaging the intake manifold and coolant pipe, this pro‐
cedure must be carried out very carefully!
– Insert a flat-blade screwdriver into the slot -arrow 1-.
– Carefully push screwdriver in direction of -arrow 2-. At the

same time, raise coolant pipe -4- in direction of -arrow 3-.
– Raise coolant pipe -1- further in direction of -arrow-. Detach

coolant pipe from fastener -2-.
Installing
3. Coolant pipes 255

– First push coolant pipe onto mounting -1- until it engages.

– Then push coolant pipe onto mounting -2- until it engages.
– Check that the coolant pipe has properly engaged by pulling
on it.
served:
Note
♦ Renew seals and O-rings.


Torque settings
♦ ⇒ “4.1 Assembly overview - intake manifold”, page 310

4 Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 257
⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page
259
⇒ “4.3 Removing and installing radiator”, page 260
⇒ “4.4 Removing and installing water radiator for charge air cool‐
ing circuit”, page 263
page 267
⇒ “4.6 Removing and installing radiator fan V7 ”, page 268
4.1 Assembly overview - radiator/radiator fan
Note
The arrows on the coolant pipes and on the ends of the coolant hoses must align.
1 - Radiator mounting
❑ Lower radiator mount‐
ing in front end
2 - Radiator for charge air cool‐
ing circuit
stalling water radiator
for charge air cooling
circuit”, page 263
3 - Radiator outlet coolant tem‐
perature sender - G83-
stalling radiator outlet
coolant temperature
sender G83 ”, page 250
❑ 35 Nm
4 - O-ring
❑ Check for damage, and
renew if necessary; see
⇒ Electronic parts cata‐
logue (ETKA)
5 - Bolt
❑ 5 Nm
❑ Qty. 2
6 - Radiator mounting
❑ Top
7 - Radiator/cooler
❑ After renewing, renew entire coolant
4. Radiator, radiator fan 257

8 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 220
9 - Expansion tank
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
system tester - V.A.G 1274/8-
10 - 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
11 - Bolt
❑ 2 Nm
❑ Qty. 2
12 - Connector
13 - Radiator cowl with radiator fan - V7-
❑ Assembly overview ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page 259
❑ Removing and installing ⇒ “4.5 Removing and installing radiator cowl with radiator fan”, page 267
❑ With radiator fan control unit - J293-
14 - Coolant hose
❑ Connection diagram ⇒ “1.1 Connection diagram - coolant hoses”, page 220
Connecting coolant hose with plug-in connector

– Check seal -2- for damage, and renew if necessary; see ⇒
Electronic parts catalogue (ETKA) .
– Moisten O-ring with coolant, and insert it into coolant hose.
– Push coolant hose into connection -1- until it audibly engages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.

4.2 Assembly overview - radiator cowl and radiator fan
1 - Air guide ring

2 - Radiator fan - V7-
stalling radiator fan V7 ”,
page 268
3 - Radiator cowl
stalling radiator cowl
with radiator fan”,
page 267
4 - Nut
❑ 8 Nm
❑ Qty. 3
5 - Bracket
❑ For electrical connector
6 - Connector
❑ For radiator fan - V7- .
7 - Spreader rivet
❑ For securing air guide
ring
❑ Qty. 4

4.3 Removing and installing radiator

equipment required
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Guide pins - 3411-
Note
♦ Radiator and charge air cooler are separate components.

♦ Radiator is mounted onto charge air cooler.
♦ Assembly overview - parts of cooling system, body side
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 257 .
Removing
– Drain coolant from radiator


page 267 .
Vehicles with air conditioner:
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Moving to and from service
position .
– Release and pull off connector -2- on radiator outlet coolant
temperature sender - G83- -1-.
– Open spring-type clip -arrow- and pull off coolant hose down‐
wards.

– Pull upper coolant hose -1- off radiator -2-.

– Unscrew securing bolts -arrows-.

– Lift radiator out of lower mountings and press it slightly towards
rear.
Vehicles with air conditioning system
CAUTION

– Do not stretch, kink or bend refrigerant lines and hoses.
– Place condenser in lock carrier at front and secure it in place
to prevent it from falling down.
Note
In order to avoid damage to the charge air cooler, 2 mechanics

should work together when disconnecting.
– Push a wide flat-bladed screwdriver at front and rear into the

left fastener on the water radiator for charge air cooling circuit
-1-.
– Open latch by turning screwdriver in -direction of arrow A-.
– In this position, slightly pull water radiator for charge air cooling
circuit -1- on left side in -direction of arrow B- off radiator -2-.

– Lower water radiator for charge air cooling circuit -1- further in
-direction of arrow A-.
– At the same time, push radiator for charge air cooling circuit
-1- in -direction of arrow B-.
– Detach water radiator for charge air cooling circuit -1- on right
from mounting -arrow- on radiator -2-.
– Secure water radiator for charge air cooling circuit -1- to pre‐
vent it from falling down.
– Removing radiator.
Installing
served:
– Insert water radiator for charge air cooling circuit -2- into right
mounting.
– Properly engage water radiator for charge air cooling circuit
-2- in -direction of arrow- in mountings on radiator -1-.
– Check firm seating by pulling.
Note
♦ If there are minor dents in the fins, refer to

⇒ “3.5 Fitting radiator and condensers”, page 5 .
♦ Renew O-rings.
– Install front bumper cover ⇒ General body repairs, exterior;

page 267 .
Note
Torque settings
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 257
4.4 Removing and installing water radiator

for charge air cooling circuit
Note
♦ Radiator and charge air cooler are separate components.

♦ Radiator is mounted onto charge air cooler.
♦ Assembly overview - parts of cooling system, body side
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 257 .


equipment required
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Guide pins - 3411-
Removing
– Clamp off coolant hoses leading to water radiator for charge
air cooling circuit using hose clamps, up to 25 mm - 3094- .
– Drain coolant from water radiator for charge air cooling circuit


– Pull hoses -1- off water radiator for charge air cooling circuit
-2-.
page 267 .
– Release and pull off connector -2- on radiator outlet coolant

temperature sender - G83- -1-.
– Remove front bumper cover ⇒ General body repairs, exterior;
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Moving to and from service
position .
– Unscrew securing bolts -arrows-.

– Lift radiator out of lower mountings and press it slightly towards
rear.
Vehicles with air conditioning system
CAUTION

– Place condenser in bonnet lock latch at front and secure with
cable ties to prevent it from falling.
– Secure radiator -1- to prevent it from falling.
Note
In order to avoid damage to the charge air cooler, 2 mechanics

are needed to disconnect the charge air cooler from radiator.

– Push a wide flat-bladed screwdriver at front and rear into the

left fastener on the water radiator for charge air cooling circuit
-1-.
– Open latch by turning screwdriver in -direction of arrow A-.
– In this position, slightly pull water radiator for charge air cooling
circuit -1- on left side in -direction of arrow B- off radiator -2-.
– Lower water radiator for charge air cooling circuit -1- further in
-direction of arrow A-.
– At the same time, push radiator for charge air cooling circuit
-1- in -direction of arrow B-.
– Detach water radiator for charge air cooling circuit -1- on right
from mounting -arrow- on radiator -2-.
– Remove water radiator for charge air cooling circuit -1- down‐
wards.
Installing
served:
– Insert water radiator for charge air cooling circuit -2- into right
mounting.
– Properly engage water radiator for charge air cooling circuit
-2- in -direction of arrow- in mountings on radiator -1-.
– Check firm seating by pulling.
Note
♦ If there are minor dents in the fins, refer to

♦ Renew O-rings.
– Install front bumper cover ⇒ General body repairs, exterior;

page 267 .
Note
Torque settings

4.5 Removing and installing radiator cowl

with radiator fan
Removing
– Undo bolts -arrows- for air intake -1-.
– Remove connecting hose -2- leading to air filter
⇒ “3.1 Assembly overview - air filter housing”, page 307 .
– Separate connector -arrow-.
– Open hose guides on cowling -2-.

– Push coolant hose -1- to one side.

– Disengage cowling with radiator fan - V7- from locking hook

using a suitable tool.
– Push cowling together with radiator fan - V7- upwards out of
the mountings and remove downwards.
Installing
served:
– Move radiator cowling together with radiator fan - V7- to in‐
stallation position from below.
– Push evenly into all four mountings from above.
• The fan frame must engage audibly on the right and left at the
top.
– Check that it has engaged securely by pulling on it.
Torque settings
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 307 .
4.6 Removing and installing radiator fan -

V7-
Removing
page 267 .
– Remove connector for radiator fan from retainer.
– Push pins out of spreader rivets -arrows-.
– Carefully lift up fan ring on back of radiator cowling using a

suitable tool.
– Remove fan ring.

– Remove electric cable -1- from cable guide.

– Unscrew nuts -arrows- and remove radiator fan - V7- .
Installing
served:
– Ensure proper seating of spreader rivets -arrows-.

page 267 .
Torque settings
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 259

21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.2 Removing and installing turbocharger”, page 274
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 277
page 279
1.1 Assembly overview - turbocharger

⇒ “1.1.1 Assembly overview - turbocharger, version 1”,
page 270
⇒ “1.1.2 Assembly overview - turbocharger, version 2”,
page 271
⇒ “1.1.3 Assembly overview - lines on turbocharger”, page 273
1.1.1 Assembly overview - turbocharger, version 1
page 274
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
270 Rep. gr.21 - Turbocharging/supercharging

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 ⇒ “1.3 Removing and installing charge pressure positioner V465 ”, page 277
1.1.2 Assembly overview - turbocharger, version 2
1 - Bolt
❑ 25 Nm
2 - Bolt/nut
❑ 8 Nm
3 - Heat shield
page 274
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°
1. Exhaust turbocharger 271

Note
If one ore more of the bolts are

loose, always renew all 3 bolts.
Note
♦ Note the following when instal‐

ling!
♦ There may be different types of
charge air pressure controllers
installed.
14 - Bolt
❑ 8 Nm
15 - Union
❑ Removing and installing ⇒ “1.4 Removing and installing connection for turbocharger”, page 279
16 - O-ring
❑ Before installing, moisten lightly with clean engine oil.
17 - Seal
❑ Renew

1.1.3 Assembly overview - lines on turbocharger
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
❑ Check for damage, and
renew if necessary; see
⇒ Electronic parts cata‐
logue (ETKA)
11 - Hose
tion.
12 - Bolt
❑ 5 Nm
13 - O-ring
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 274
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


Removing
Note
♦ If a mechanical fault is discovered on the turbocharger (e.g. a
destroyed compressor impeller), it is not sufficient to just re‐
new 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 for‐
eign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the charge
air cooler.
♦ Do not reuse coolant which has been drained off.
– Drain coolant
– Remove heat shield for drive shaft ⇒ Running gear, axles,
drive shaft heat shield .


– Remove oil supply line -1- and oil return line -2-.

309 .
– Remove air pipe
Note


– Remove crankcase breather hose and place it to one side.
– Remove crankcase breather -1- from camshaft housing -2-.

– Lay crankcase breather -1- to one side.
page 279 .


– Swivel coolant lines -1- to side.

– Unclip wiring harness for lambda probe from heat shield -1-.
– Remove heat shield -1-.
– Unscrew nuts -arrows- and remove turbocharger.

Installing
served:
Note
♦ Renew seals, O-rings and securing nuts of cylinder head.

♦ Before installing, lightly moisten O-rings with clean engine oil.
♦ Renew clamps for attaching catalytic converter to turbocharg‐
er.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.

– Fit screwdriver -2- in recess -arrow- on turbocharger.

– Lever out seal -1-.
– Renew oil seal -1-.
– Ensure proper connection and routing of wires ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Torque settings
1.3 Removing and installing charge pres‐

sure positioner - V465-
⇒ “1.3.1 Removing and installing charge pressure positioner
V465 , version 1”, page 277
⇒ “1.3.2 Removing and installing charge pressure positioner
V465 , version 2”, page 278
1.3.1 Removing and installing charge pres‐

sure positioner - V465- , version 1
Removing
sulation .


– Remove securing clip -2-.
– Remove bolts -arrows- and detach charge pressure positioner
- V465- .
Installing
Always renew securing bolts and the securing clip.
Note
There may be different types of charge air pressure controllers

installed.
Charge pressure positioner without adjustable linkage:

– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; “Guided functions” .
Charge pressure positioner with adjustable linkage:
– Fit thread of charge pressure positioner -V465- at central po‐
sition in joint element.
– Adjust charge air pressure controller - V465- : ⇒ Vehicle diag‐
nostic tester Select 01 - Adjust charge air pressure
controller V465 in Guided functions .
– Adjust to specified value by turning linkage. For specified val‐

ue, see ⇒ Vehicle diagnostic tester.
– Tighten lock nut to 6 Nm and secure with sealing paint.
Torque settings
♦ ⇒ “1.1.1 Assembly overview - turbocharger, version 1”,
page 270
1.3.2 Removing and installing charge pres‐

sure positioner - V465- , version 2
Removing
sulation .
309 .
– Remove air pipe

– Open hose clip -1- and push coolant hose -2- to one side.
– Unscrew bolts -arrows- and remove crankcase breather hose.
page 279 .
– 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.
Renew O-rings after removal.
Before installing, lightly moisten O-rings with clean engine oil.
Charge air pressure controller without adjustable linkage
– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; “Guided functions” .
Charge air pressure controller with adjustable linkage
– Fit thread of charge pressure positioner -V465- at central po‐
sition in joint element.
– Adjust charge air pressure controller - V465- : ⇒ Vehicle diag‐
nostic tester Select 01 - Adjust charge air pressure
controller V465 in Guided functions .
– Adjust to specified value by turning linkage. For specified val‐

ue, see ⇒ Vehicle diagnostic tester.
– Tighten lock nut to 6 Nm and secure with sealing paint.
Torque settings
♦ ⇒ “1.1.2 Assembly overview - turbocharger, version 2”,
page 271
1.4 Removing and installing connection for

turbocharger

♦ Torx bit T30 - T10573-
♦ Socket Torx T 30 - T10405-

♦ Ratchet insert 1/4" - VAS 6234-

309 .
– Remove air pipe
– Release and pull off electrical connectors -1- on coolant tem‐
perature sender - G62- .
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.
– Unscrew bolts -arrows- using insert tool - T10572- and Torx

bit T30 - T10573- .
– Remove support -1-.
Installing:
Note
♦ Renew seals, O-rings and securing nuts of cylinder head.

♦ Before installing, lightly moisten O-rings with clean engine oil.
– Tighten bolts using insert tool - T10572- , Torx bit T30 -

T10573- and torque wrench - V.A.G 1783- .
– Set torque wrench - V.A.G 1783- to 4.2 Nm.
Torque settings

2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 283
⇒ “2.2 Removing and installing charge air cooler”, page 285
⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 286
⇒ “2.4 Checking charge air system for leaks”, page 287
⇒ “2.5 Removing and installing air intake pipe”, page 289
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.
1 - O-ring
moisten O-ring with
clean engine oil
2 - Union
3 - O-ring
moisten O-ring with
clean engine oil
4 - Air intake pipe
stalling air intake pipe”,
page 289
5 - Charge air pressure sender
- GX26-
❑ Consisting of
Charge pressure sender
- G31-
Intake air temperature

sender - G42-
stalling charge pressure
sender GX26 ”,
page 286
6 - O-ring
❑ Not sold separately
❑ If damaged, renew
charge pressure sender
- GX26- Volkswagen Technical Site: http://vwts.ru http://vwts.info
7 - O-ring
❑ Before installing, lightly moisten O-ring with clean engine oil
2. Charge air system 283

8 - Bolt
❑ Thread-forming
❑ 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 ⇒ “4.3 Removing and installing throttle valve module GX3 ”, page 314
11 - Seal
12 - Intake manifold
Removing and installing ⇒ “4.2 Removing and installing intake manifold”, page 312
13 - Seal
❑ Renew
14 - Sealing lip
❑ Before installing, moisten lightly with clean engine oil.
15 - Coolant hose
16 - Clip
17 - Charge air cooler
❑ Change coolant after renewing
18 - Bolt
❑ Thread-forming
❑ 15 Nm
19 - Coolant hose
20 - Clip
21 - Coolant hose
22 - Clip
23 - Bolt
❑ Specified torque and tightening sequence ⇒ “4.1 Assembly overview - intake manifold”, page 310
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 ⇒ “5.3 Removing and installing intake manifold sender GX9 ”, page 321
26 - Seal
❑ Qty. 4
2.2 Removing and installing charge air cool‐

er
Removing
– Observe rules for cleanliness
⇒ “1.1 Safety regulations for working on fuel supply”, page 1 .
– Remove air filter
page 267 .


– Clamp off coolant hoses -1- on charge air cooler using hose
clamps, up to Ø 25 mm - 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
served:
– Fit sealing lip -1- in -direction of arrow- onto charge air cooler
-2-.
Note
If there are minor dents in the fins, refer to

– Insert new gasket into groove on intake manifold.
– Tighten bolts -arrows- alternately and diagonally working from

centre outwards.
– Install hose clips -1-.
page 267 .
Torque settings
2.3 Removing and installing charge pres‐

sure sender - GX26-
The charge pressure sender - GX26- comprises the charge pres‐
sure sender - G31- and the intake air temperature sender - G42- .

Removing
– Release fasteners -arrows-, and remove charge pressure
sender - GX26- .
Installing
served:
Note
♦ Renew O-ring.
♦ If the retaining tabs broke off during removal, the sender can
be mounted using two securing bolts ⇒ Electronic parts cata‐
logue . Specified torque: ⇒ page 287
Torque setting

Charge pressure sender - GX26- 3 Nm
2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
Procedure
309 .
charcoal filter.
Note
Risk of chemical damage to coolant pump seal from oil ingress

between coolant pump and cylinder head.
– Cover coolant pump with a cloth to collect any escaping oil.

– Seal open connection of turbocharger using a suitable plug

– 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 the pressure regulating valve -2- the 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 to engine
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 by hearing, touching, with
commercially available leak detector spray or using ultrasonic
tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ For information on how to use the ultrasonic tester - V.A.G
1842- refer to respective ⇒ operating manual .
♦ Before removing the adapter, release pressure in the test cir‐
cuit by pulling off hose coupling.
Installing
Assemble in reverse order of dismantling. The following should
be observed:
Note
Renew seal and O-rings.

2.5 Removing and installing air intake pipe


– Unclip vacuum hose on air intake pipe -2-.
– Release and pull off connector -arrow- of charge pressure

sender - GX26- -1-.
– Open hose clips -arrows- and detach air duct -1-.

– Release fasteners -arrows- using release tools - T10527- and

-T10527/1- .
– Remove air intake pipe -1-.

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 291
1.1 Overview of fitting locations - injection

system
⇒ “1.1.1 Overview of fitting locations - engine compartment, ve‐
hicles with Active Cylinder Management”, page 291
⇒ “1.1.2 Overview of fitting locations - engine compartment, ex‐
haust side with toothed belt pulley”, page 294
⇒ “1.1.3 Engine (from above), vehicles with Active Cylinder Man‐
agement”, page 296
⇒ “1.1.4 Overview of fitting locations - front view of engine”, page
297
⇒ “1.1.5 Overview of fitting locations - rear view of engine”, page
298
1.1.1 Overview of fitting locations - engine compartment, vehicles with Active

Cylinder Management
1. Injection system 291


1 - N205-
installing camshaft con‐
trol valve 1 N205 , ex‐
haust side with toothed
belt pulley”, page 178
2 - Exhaust camshaft control
valve 1 - N318-
3 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ Consisting of
Lambda probe - G39-
Lambda probe heater -

Z19-
stalling Lambda probe”,
page 334
4 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ Consisting of
Lambda probe after cat‐
alytic converter - G130-
Lambda probe 1 heater

after catalytic converter -
Z29-
❑ Removing and installing ⇒ “8.2 Removing and installing Lambda probe”, page 334
❑ Removing and installing ⇒ “3.8 Removing and installing cam actuators”, page 187
10 - Radiator outlet coolant - G62-
❑ Removing and installing ⇒ “2.8 Removing and installing coolant temperature sender G62 ”, page 248
❑ Removing and installing ⇒ “1.4.2 Removing and installing Hall sender 3 G300 ”, page 353
292 Rep. gr.24 - Mixture preparation - injection

13 - Engine control unit - J623-
❑ Removing and installing ⇒ “6 Engine control unit”, page 323
❑ 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 control - G187-
16 - Charge air pressure sender - GX26-
❑ Consisting of
Charge pressure sender - G31-
Intake air temperature sender - G42-

❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 286
❑ Consisting of

❑ Assembly overview ⇒ “4.1 Assembly overview - intake manifold”, page 310
❑ Removing and installing ⇒ “5.3 Removing and installing intake manifold sender GX9 ”, page 321
19 - Ignition coils with output stages
♦ Ignition coil 1 with output stage - N70-
❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stage”, page 349

1.1.2 Overview of fitting locations - engine compartment, exhaust side with tooth‐
ed belt pulley

1 - N205-
stalling camshaft control
valve 1 N205 ”,
page 178
❑ Consisting of
Lambda probe - G39-

Z19-
view - Lambda probe”,
page 333
❑ Consisting of

Z29-
view - Lambda probe”,
page 333
4 - Charge air pressure con‐
troller - V465-
stalling charge pressure positioner V465 ”, page 277
5 - Engine control unit - J623-
❑ Removing and installing ⇒ “6 Engine control unit”, page 323
7 - Hall sender - G40- (camshaft position sender)
❑ Assembly overview ⇒ “1.1 Assembly overview - ignition system”, page 348
❑ Consisting of
Throttle valve module - J338-
Throttle valve drive for electronic power control - G186-

9 - Charge air pressure sender - GX26-
❑ Consisting of
Charge pressure sender - G31-
Intake air temperature sender - G42-

❑ Consisting of

12 - Ignition coils with output stages

1.1.3 Engine (from above), vehicles with Active Cylinder Management
1 - Exhaust camshaft control

valve 1 - N318-
2 - Ignition coil 1 with output
stage - N70-
stalling ignition coils
with output stage”, page
349
stage - N127-
349
cylinder 2 - N587-
page 187
stage - N291-
349
cylinder 3 - N595-
8 - Ignition coil 4 with output stage - N292-
10 - High-pressure pump
❑ Assembly overview ⇒ “7.1 Assembly overview - high-pressure pump”, page 326
❑ Removing and installing ⇒ “7.2 Removing and installing high-pressure pump”, page 330

13 - Inlet camshaft control valve 1 - N205-

⇒ “3.5.2 Removing and installing camshaft control valve 1 N205 , exhaust side with toothed belt pulley”,
page 178
1.1.4 Overview of fitting locations - front view of engine
1 - Knock sensor 1 - G61-

view - ignition system”,
page 348
2 - Oil pressure switch for re‐
duced oil pressure - F378-
switch for reduced oil
pressure F378 ”,
page 215
3 - Fuel pressure sender -
G247-
view - fuel rail with injec‐
tors”, page 299
4 - Activated charcoal filter sol‐
enoid valve 1 - N80-
5 - Injectors
♦ Injector, cylinder 1 - N30-
view - fuel rail with injec‐
tors”, page 299
6 - Fuel pressure regulating
valve - N276-
❑ On high-pressure pump
❑ Assembly overview ⇒ “7.1 Assembly overview - high-pressure pump”, page 326
7 - Engine speed sender - G28-
❑ Assembly overview ⇒ “1.1 Assembly overview - ignition system”, page 348

1.1.5 Overview of fitting locations - rear view of engine
1 - Oil level and oil temperature

sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 205
G62-
stalling coolant temper‐
ature sender G62 ”,
page 248
3 - Oil pressure switch - F1-
switch F1 ”, page 214
4 - Valve for oil pressure con‐
trol - N428-
stalling oil pressure reg‐
ulating valve N428 ”,
page 218

2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 299
⇒ “2.2 Removing and installing fuel rail”, page 300
⇒ “2.3 Removing and installing injectors”, page 301
⇒ “2.4 Cleaning injectors”, page 306
2.1 Assembly overview - fuel rail with injectors
1 - Fuel pressure sender -

G247-
❑ Checking
⇒ “5.2 Checking fuel
pressure sender G247 ”,
page 318
stalling fuel pressure
sender G247 ”,
page 317
❑ Lubricate taper lightly
with clean engine oil; do
not lubricate thread
❑ 22 Nm
2 - Fuel distributor
stalling fuel rail”,
page 300
3 - High-pressure pipe
stalling high-pressure
pipe”, page 331
❑ Unions must be free of
damage
❑ Do not alter shape.
❑ Lubricate thread of un‐
ion nuts with clean en‐
gine oil
❑ 16 Nm +45°
4 - Bolt
❑ Removing and installing ⇒ “2.2 Removing and installing fuel rail”, page 300
❑ 8 Nm +90°
5 - Support ring
❑ Fuel rail exerts force which secures injector in cylinder head via this support ring
❑ Clipped to -item 8-
6 - O-ring
❑ Lubricate with clean engine oil
2. Injectors 299
7 - Spacer ring
8 - Injection valve
❑ Removing and installing ⇒ “2.3 Removing and installing injectors”, page 301
❑ Assembly overview ⇒ page 300
9 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
❑ Renewing ⇒ “2.3 Removing and installing injectors”, page 301
Assembly overview - injector

1- Injection valve
2- Spacer ring
3- O-ring
4- Support ring
5- Sealing element (top)
6- Sealing element (bottom)
7- Retaining ring
8- Combustion chamber seal
2.2 Removing and installing fuel rail

Removing
– Remove high-pressure pipe
page 331 .

Note
Place a cloth underneath to catch escaping fuel.
– Remove bolts -arrows- and pull fuel rail off injectors.

Installing
served:
Note
Renew O-ring.
– 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.
– Install high-pressure pipe
page 331 .
Torque settings
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 299
2.3 Removing and installing injectors

♦ Tool set for FSI engines - T10133- with -T10133/16 A- and -
T10133/19-
Removing
Note
Injectors must only be removed when the engine is cold.

2. Injectors 301
– Removing fuel rail

⇒ “2.2 Removing and installing fuel rail”, page 300 .
– 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 -T10133/18- over injector.

– 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 the injector
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.
♦ 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-.
– Remove retaining ring -7-, upper sealing washer -5- and lower
sealing washer -6-.
– Carefully remove old combustion chamber seal -8-.
– To do this, cut the ring open using a knife or spread the ring
using a screwdriver and pull it off towards front.
– Pull off the ring towards front.
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.
2. Injectors 303
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 injector, clean groove for combustion cham‐

ber seal and injector shaft. To do this, use a clean cloth to
remove combustion residue.
– 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.
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 opposite
direction.
– Push calibration sleeve -T10133/8- onto injector as far as stop

and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again, turning in opposite
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 in‐
jectors 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 re‐

cess in cylinder head.
– Installing fuel rail
⇒ “2.2 Removing and installing fuel rail”, page 300 .
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition, and select following menu item on ⇒ Vehi‐
cle diagnostic tester:
♦ 0001 - Clear adaption values for injectors
2. Injectors 305
2.4 Cleaning injectors

♦ Ultrasonic cleaning device - VAS 6418-
♦ Mounting plate for injectors - 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 safety instructions and operating instructions for ul‐
trasonic unit.
Cleaning
– Remove injectors
⇒ “2.3 Removing and installing injectors”, page 301 .
– Insert injectors -1- as far as stop into mounting plate for injec‐
tion modules - VAS 6418/1- -item 2-.
– Immerse injectors together with mounting plate injection mod‐
ules - 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-.
– Press button -3- to switch on ultrasonic unit.
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 ⇒ “2.3 Removing and installing injectors”, page 301 .

3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 307
⇒ “3.2 Removing and installing air filter housing”, page 308
⇒ “3.3 Removing and installing resonator for intake air”,
page 309
3.1 Assembly overview - air filter housing
1 - Connection hose
2 - Intake connecting pipe
❑ On lock carrier.
3 - Bolt
❑ 2 Nm
4 - Water drainage pipe
❑ Clean if soiled.
5 - Bolt
❑ 1.5 Nm
6 - Bump stop
7 - Air filter lower part
❑ Remove dirt, leaves and
salt residues
8 - Air filter element
❑ Use only genuine air fil‐
ter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance ta‐
bles
⇒ Maintenance ; Book‐
let
9 - Air filter upper part
❑ Remove dirt, leaves and
salt residues
10 - Hose
tion.
11 - Air intake hose
12 - Clip
3. Air filter 307

3.2 Removing and installing air filter hous‐

ing
Removing
– Detach air hose -2-.
– Pull air filter housing -1- off ball head pins upwards.
– Release hose clips -3- and -4- and remove air ducts.
– First pull air filter housing off ball stud -C-.

– Then, and only then, pull air filter housing off ball studs -B- and
-A-.
Installing
• 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-.
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 as a smaller in‐
jection 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.
♦ Cover the critical air-conducting components such as air pipes
etc. with a clean cloth when blowing out the air filter housing
with compressed air.
♦ 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.
Torque settings
3.3 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 309

4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 310
⇒ “4.2 Removing and installing intake manifold”, page 312
⇒ “4.3 Removing and installing throttle valve module GX3 ”, page
314
⇒ “4.4 Cleaning throttle valve module GX3 ”, page 315
4.1 Assembly overview - intake manifold
1 - Coolant pipe
manifold.
❑ To remove, remove in‐
take manifold
page 312
2 - Intake manifold
❑ Combined with charge
air cooler
page 312
3 - Coolant pipe
manifold.
4 - Bolt
tightening sequence
⇒ page 311
5 - O-ring
6 - Intake manifold sender -
GX9-
❑ Consisting of
Intake air temperature
sender 2 - G299-
Intake manifold pressure

sender - G71-
⇒ “5.3 Removing and installing intake manifold sender GX9 ”, page 321
7 - Seals
8 - Charge pressure sender - GX26-
❑ Consisting of
♦ Charge pressure sender - G31-
♦ Intake air temperature sender - G42-
❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender GX26 ”, page 286

9 - O-ring
10 - Union
11 - O-ring
❑ Before installing, moisten lightly with clean engine oil
12 - Air intake pipe
❑ For removal, use release tool - T10527- and release tool - T10527/1-
13 - O-ring
❑ Renew
❑ Before installing, moisten lightly with clean engine oil
14 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to torque.
❑ 7 Nm
15 - Retaining clip
❑ For air intake pipe
❑ Throttle valve module - GX3- consists of
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module GX3 ”, page 315
17 - Seal
18 - Vacuum line
19 - O-ring
❑ If O-ring is damaged, renew vacuum line ⇒ Electronic parts catalogue
20 - Vacuum line
21 - O-ring
❑ If O-ring is damaged, renew vacuum line ⇒ Electronic parts catalogue
Intake manifold - specified torque and tightening sequence

– Tighten bolts in stages as follows:
1. -Arrows- Starting in centre, screw in bolts alter‐
nately by hand until they make contact
2. -Arrows- Starting in centre, screw in bolts alter‐
nately to 8 Nm
4. Intake manifold 311

4.2 Removing and installing intake manifold

Removing
– Drain coolant
Note
CAUTION
– First press hose connector -1- downwards, and then press re‐
lease tabs -arrows-.
– Keep release buttons pressed and pull off hose coupling.
– Press release tab on hose -2- for activated charcoal filter.
– Disconnect hose and move it clear.
– Release catch -arrow- and disconnect vacuum hose -1-.

– Move clear vacuum hose at air intake pipe -2-.
– Move clear air hoses at charge air pipe.
– Remove air pipe

– Clamp off coolant hoses on coolant pipe using hose clamps

up to 25 mm - 3094- .
– Release hose clips -arrows-.
– Pull off coolant hoses.
– Separate electrical connectors.

1 - For activated charcoal filter system solenoid valve 1 - N80-
3 - For throttle valve module - GX3-
4 - For intake manifold sender - G71- .
– Unscrew bolt -arrow-.
– Press release buttons and pull off hose -2- for activated char‐
coal 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
served:
Note
Renew seals and O-rings.

Torque settings
4.3 Removing and installing throttle valve

module - GX3-
Throttle valve module - GX3- consists of
♦ Throttle valve drive angle sender 1 for electronic power control
- G187-
♦ Throttle valve drive angle sender 2 for electronic power control
- G188-
Removing
– Remove air pipe
– Open hose clips -arrows- and detach air duct -1-.


– Unscrew bolts -arrows- and remove throttle valve module -
GX3- -1- with adapter -2-.
Installing
served:
– After renewing throttle valve module - GX3- , re-adapt it to en‐
gine control unit - J623- . Use ⇒ Vehicle diagnostic tester.
– Switch on ignition, and select following menu item on the ve‐
hicle diagnostic tester :
♦ 0001 - Adaption throttle valve module J338
Torque settings
4.4 Cleaning throttle valve module - GX3-
Note
♦ If a new engine control unit - J623- is installed, the throttle

valve module must be adapted.
♦ 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
Procedure
– Remove throttle valve module - GX3-
⇒ “4.3 Removing and installing throttle valve module GX3 ”,
page 314 .
– 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 com‐
mercially 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-
page 314 .
– Delete learnt values, and adapt engine control unit - J623- to
throttle valve module - GX3- . Use ⇒ Vehicle diagnostic tester.
– Switch on ignition, and select following menu item on the ve‐
hicle diagnostic tester :
♦ 0001 - Adaption throttle valve module J338

5 Senders and sensors

⇒ “5.1 Removing and installing fuel pressure sender G247 ”, page
317
⇒ “5.2 Checking fuel pressure sender G247 ”, page 318
⇒ “5.3 Removing and installing intake manifold sender GX9 ”,
page 321
5.1 Removing and installing fuel pressure

sender - G247-
♦ Socket 27 mm - T40218- or commercially available 27 mm

hexagon socket insert
5. Senders and sensors 317

Removing
Note
Place a cloth underneath to catch escaping fuel.
– Unscrew fuel pressure sender - G247- -2- using socket 27 mm

- T40218- .
Installing
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 299
Note
Do not lubricate thread of fuel pressure sender.
5.2 Checking fuel pressure sender - G247-

⇒ “5.2.1 Checking fuel pressure sender G247 , using pressure
sensor tester VAS 6394 and vehicle diagnostic tester”,
page 318
⇒ “5.2.2 Checking fuel pressure sender G247 , using vehicle di‐
agnostic tester”, page 320
5.2.1 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

Procedure
CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– Release high pressure.
– Remove fuel pressure sender - G247-

⇒ “5.1 Removing and installing fuel pressure sender G247 ”,
page 317 .
– 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- electrically

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 ⇒ 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 displayed on tester -VAS 6394/1- with ac‐
tual value 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 engine
control unit - J623- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Torque settings
5.2.2 Checking fuel pressure sender - G247- ,

using vehicle diagnostic tester
♦ Pressure gauge - VAS 6550-
♦ ⇒ Vehicle diagnostic tester

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
The fuel system is pressurised.
Danger of injury caused by fuel spray.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
– 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 sender
- 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
5.3 Removing and installing intake manifold

sender - GX9-
Intake manifold sender - GX9- consists of:
♦ Intake air temperature sender 2 - G299-
♦ Intake manifold pressure sender - G71-
Removing


– Release fasteners -arrows-.
– Remove intake manifold sender - GX9- .
Installing
served:
Note
♦ Renew O-ring.
♦ If the retaining tabs broke off during removal, the sender can
be mounted using two securing bolts ⇒ Electronic parts cata‐
logue . Specified torque: ⇒ page 322 .
Torque setting

Intake manifold sender - GX9- 3 Nm


6 Engine control unit

⇒ “6.1 Removing and installing engine (motor) control unit J623
”, page 323
⇒ “6.2 Removing and installing engine (motor) control unit J623
with protective housing”, page 324
6.1 Removing and installing engine (motor)

control unit - J623-
When renewing engine control unit:
– Connect vehicle diagnostic tester .
– Perform function 0001 - Engine control unit renewal .
Removing
Note
If the engine (motor) control unit comes into contact with the pos‐
itive battery terminal, permanent damage to the engine (motor)
control unit will be the consequence. For this reason, disconnect
the battery prior to removing the engine control unit from its brack‐
et.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Release -arrow- connectors from engine control unit and pull
off.
6. Engine control unit 323

– Press clips -arrows A- outwards and pull engine control unit

out to side -B-.
Installing
– Insert new engine control unit and press to left.
– Connect connectors and lock.
– Select function 0001 - Entry in event memory .
– Clear event memory.
– Carry out road test.
– Read event memory again.
If engine control has been renewed:
Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
– Select function 0001 - Engine control unit renewal .
6.2 Removing and installing engine (motor)

control unit - J623- with protective hous‐
ing
When renewing engine control unit:
– Perform function 0001 - Engine control unit renewal .
Removing
Note
If the engine (motor) control unit comes into contact with the pos‐
itive battery terminal, permanent damage to the engine (motor)
control unit will be the consequence. For this reason, disconnect
the battery prior to removing the engine control unit from its brack‐
et.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Open line guide -1- and raise catch -2-.
– Remove engine control unit from its bracket.

– Unscrew shear-head bolt -1- using a pair of pliers.

– Turn engine control unit -2- around and also unscrew second
shear-head bolt using a pair of pliers.
– Pull bracket -1- and protective housing -2- off engine control
unit -3- in -direction of arrow-.
– Release connector from engine control unit and pull off.
Installing
– Attach and lock connectors.
– Push protective housing over engine control unit.
– Install protective housing bracket with new shear bolts.
– Clean the threaded holes for the shear-head bolts of locking
compound residues. A thread chaser is suitable for cleaning.
– Tighten shear-head bolts evenly until bolt head breaks off.
– Insert engine control unit into mounting bracket on plenum

chamber bulkhead until it audibly engages in catch -1-.
– Press line into line guide -1- and close.
– Select function 0001 - Entry in event memory .
– Clear event memory.
– Carry out road test.
– Read event memory again.
If engine control has been renewed:
Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
– Select function 0001 - Engine control unit renewal .
6. Engine control unit 325

7 High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 326
⇒ “7.2 Removing and installing high-pressure pump”, page 330
⇒ “7.3 Removing and installing high-pressure pipe”, page 331
7.1 Assembly overview - high-pressure

pump
⇒ “7.1.1 Assembly overview - high-pressure pump, version 1”,
page 326
page 328
page 329
7.1.1 Assembly overview - high-pressure pump, version 1
1 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
2 - O-ring
❑ Renew
❑ Coat lightly with clean
engine oil when instal‐
ling.
❑ With fuel pressure regu‐
❑ Do not dismantle.
pump”, page 330
damage
pipe”, page 331
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M8x32
❑ Renew

6 - Hose clamp
7 - Fuel supply line
8 - Electrical connector
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
1. -3- Screw in by hand as far as stop
2. -3- Tighten one turn alternately until
flange of high-pressure pump makes
contact with camshaft housing
3. -3- 20 Nm
4. -3- Turn 90° further
7. High-pressure pump 327

1 - Roller tappet
engine oil
2 - O-ring
❑ Renew
engine oil
pump”, page 330
❑ Renew
pipe”, page 331
damage
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M8x25
❑ Renew
6 - Hose clamp

Note

installed.

3. -3- 20 Nm
1 - Roller tappet
engine oil
2 - O-ring
❑ Renew
❑ Coat lightly with clean
engine oil when instal‐
ling.
pump”, page 330
damage
pipe”, page 331
gine oil
❑ 16 Nm +45°
5 - Bolt
❑ M6x22

❑ 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

installed.

3. -3- 8 Nm
7.2 Removing and installing high-pressure

pump
Removing
• Engine cold.
– Remove high-pressure pipe
page 331 .


– Place a cloth underneath to catch escaping fuel.
– Release hose clip -2- and detach fuel supply hose.
– Unscrew bolts -3- and detach high-pressure pump with roller
tappet.
Installing
Note

installed.
♦ Renew O-ring.
– 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.
– Note that there are different types of high-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 326 .
Variante 1 -
page 326
Variante 2 -
page 328
Variante 3 -
page 329
– Check fuel system for leaks.
7.3 Removing and installing high-pressure

pipe

♦ Insert from tool set - T10395 A-
Removing
– Remove throttle valve module - GX3-
page 314 .
– Place a cloth underneath to catch escaping fuel.
– Unscrew union nuts -arrows- and detach high-pressure pipe.
Installing
served:
– 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

insert from tool set - T10395 A- .
– Install throttle valve module - GX3-
page 314 .
Torque settings
♦ ⇒ “7.1 Assembly overview - high-pressure pump”, page 326

8 Lambda probe
⇒ “8.1 Assembly overview - Lambda probe”, page 333
⇒ “8.2 Removing and installing Lambda probe”, page 334
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, the electrical connecting cable of the Lambda probe must be secured at the same points.
♦ The wire must be prevented from touching the exhaust pipe.

❑ Consisting of

Z29-
page 334
❑ 55 Nm
❑ For Lambda probe 1 be‐
fore catalytic converter -
GX10- .
❑ For Lambda probe 1 af‐
ter catalytic converter -
GX7- .
❑ Consisting of
Lambda probe - G39-

Z19-
page 334
❑ 55 Nm
8. Lambda probe 333

8.2 Removing and installing Lambda probe

⇒ “8.2.1 Removing and installing Lambda probe 1 before catalytic
converter GX10 ”, page 334
⇒ “8.2.2 Removing and installing Lambda probe 1 after catalytic
converter GX7 ”, page 335
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-
♦ Lambda probe open ring spanner set - 3337-
Removing
– Unclip and pull off corresponding electrical connector.
– Unclip connector on retainer -1-.

– Unscrew Lambda probe 1 before catalytic converter - GX10-

-2- using tool from Lambda probe open ring spanner set -
3337- .
Installing
served:
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, the electrical connecting cable of the
Lambda probe must be secured at the same points.
Vehicles as of July 2015

– If lambda probe has been renewed, erase learnt values and
adapt lambda probe to engine control unit using ⇒ vehicle
diagnostic tester .
– Switch on ignition, and select following menu option on ⇒ Ve‐
hicle diagnostic tester:
♦ 0001 - Lambda probe adaption
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 335

Removing
– Unclip and pull off corresponding electrical connector.
– Unclip connector on retainer -1-.
– Unscrew lambda probe 1 after catalytic converter - GX7- -1-

using a suitable tool from lambda probe open ring spanner set
- 3337- .
Installing
served:
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, the electrical connecting cable of the
Lambda probe must be secured at the same points.
Vehicles as of July 2015

– If lambda probe has been renewed, erase learnt values and
adapt lambda probe to engine control unit using ⇒ vehicle
diagnostic tester .
– Switch on ignition, and select following menu option on ⇒ Ve‐
hicle diagnostic tester:
♦ 0001 - Lambda probe adaption

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 337
⇒ “1.2 Separating exhaust pipes from silencers”, page 338
⇒ “1.3 Removing and installing silencer”, page 339
⇒ “1.4 Aligning exhaust system free of stress”, page 340
⇒ “1.5 Check exhaust system for leaks”, page 341
1.1 Assembly overview - silencers
1 - Mounting
2 - Bolt
❑ 20 Nm
❑ Qty. 2
3 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
stalling silencer”,
page 339
❑ Separating exhaust
pipes from silencers
⇒ “1.2 Separating ex‐
haust pipes from silenc‐
ers”, page 338
❑ Aligning exhaust sys‐
tem free of tension
⇒ “1.4 Aligning exhaust
system free of stress”,
page 340 .
4 - Mounting
5 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
stalling silencer”, page 339
❑ Separating exhaust pipes from silencers ⇒ “1.2 Separating exhaust pipes from silencers”, page 338
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 340 .
6 - Clamping sleeve
❑ Align exhaust system free of tension before tightening
⇒ “1.4 Aligning exhaust system free of stress”, page 340 .
❑ Fitting position ⇒ page 338
1. Exhaust pipes and silencers 337

❑ Tighten threaded connections evenly.
❑ 23 Nm
7 - Mounting
Installation position of rear clamp

– Fit clamp in position shown.
• Bolted connections to right.
• Bolt -arrow- must not protrude beyond lower edge of clamp.
1.2 Separating exhaust pipes from silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipe at right angles at separating point
-arrow- using chain pipe cutter - VAS 6254- .
338 Rep. gr.26 - Exhaust system

– Position clamp centrally at side marks -arrows- when instal‐

ling.
– Fit rear clamp ⇒ page 338 .
– Align exhaust system free of stress
1.3 Removing and installing silencer

Removing
– Separate exhaust system
⇒ “1.2 Separating exhaust pipes from silencers”, page 338 .
Centre silencer
– Unscrew bolts -2- to remove bracket -4-.

– Remove middle silencer -5-.

Rear silencer
– Remove brackets -1- and -2-.
– To do this, unscrew bolts -2-.
– Guide out middle silencer -3- between rear axle and body.
Installing
served:
Torque settings
♦ ⇒ “1.1 Assembly overview - silencers”, page 337
♦ ⇒ “2.1 Assembly overview - emission control”, page 342
1.4 Aligning exhaust system free of stress

Procedure
• The exhaust system must be aligned when cold.
– Loosen bolt connections for front clamp -arrow-.
– Push exhaust system towards front of vehicle until preloading

at mounting for exhaust pipe -a- = 5 mm.
– Fit front clamp ⇒ page 343 .

Align end exhaust pipes

– Align rear silencer so that there is an equal distance -a- and
-b- between bumper cut-out and tailpipes.
– Unfasten rear silencer mounting to align tailpipes.
Torque settings
♦ ⇒ “2.1 Assembly overview - emission control”, page 342
1.5 Check exhaust system for leaks

Procedure
– 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 Exhaust gas cleaning

⇒ “2.1 Assembly overview - emission control”, page 342
⇒ “2.2 Removing and installing catalytic converter”, page 343
2.1 Assembly overview - emission control
1 - Bracket
2 - Bracket
3 - Retaining bracket
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Nut
tightening sequence
⇒ page 343
8 - Screw-type clamp
❑ Renew
tightening sequence
⇒ page 343
9 - Seal
❑ Renewing ⇒ page 343
10 - Front exhaust pipe with
catalytic converter
❑ Do not bend flexible joint
by more than 10° - risk
of damage.
❑ Install flexible joint so
that it is not under ten‐
sion
❑ Take care not to dam‐
age wire mesh on flexi‐
ble joint.
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 343
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
❑ Aligning exhaust system free of tension ⇒ “1.4 Aligning exhaust system free of stress”, page 340 .
11 - Clamping sleeve
❑ Align exhaust system free of tension before tightening
❑ Fitting position ⇒ page 338
❑ Tighten threaded connections evenly.
❑ 23 Nm

Installation position of front clamp

– Fit clamp in position shown.
• Angle -α- = approx. 20°.
• Bolted connection facing towards right.
• Nuts upwards.
Installing catalytic converter - specified torque and tightening se‐

quence
1. – Fit catalytic converter -1- to ♦ Hand-tight
turbocharger and attach new
screw-type clip -2- loosely
without tightening it.
2. – Screw on nuts -1- and -2- • It should still be
loosely by hand. possible to move
catalytic converter
and bracket.
3. – Ensure proper seating of cat‐

alytic converter -1- on turbo‐
charger.
4. – Tighten bolt -3- 15 Nm
5 – Screw nuts -4- to -6- loosely ♦ Hand-tight
onto bracket -7-.
6. – Tighten nuts in the sequence 20 Nm
-4 … 5 … 6-.
Renew seal
2.2 Removing and installing catalytic con‐

verter
Note
The catalytic converter is removed together with the front exhaust

pipe.

♦ High-temperature paste ⇒ Electronic parts catalogue .
2. Exhaust gas cleaning 343

Removing
– Remove underbody cover -1- on right and left.
– To do this, unscrew nuts -2- from studs -3-.
Note
The illustration shows the left side. The right side is similar.
– Remove tunnel cross-piece -1-.

– To do this, unscrew nuts -2- from studs -3-.
– Remove bracket -4- and lower exhaust system.

– Unbolt right drive shafts on inside ⇒ Running gear, axles,
drive shaft .
– Lay drive shaft to one side.

– Release and pull off connectors -3-.

– Lay wires -2- to one side.
– Unclip wires -4- from retainer -1-.
– Remove wires from heat shield of turbocharger.
Note
♦ Do not loosen bolts on turbocharger.

♦ Coolant lines on turbocharger are not removed.
– Unscrew nuts and bolts -arrows-.

– Thread out heat shield -1- and remove it.
– Raise coolant lines slightly when doing this.
– Remove Lambda probes
⇒ “8.2 Removing and installing Lambda probe”, page 334 .
– Detach exhaust hangers -3- in -direction of arrow- from sub‐

frame -2-.
– Lower exhaust system -1- until it rests on subframe -2-.


– Unscrew bolts -arrows- and remove bracket -1-.
– Remove heat shield -1-. To do this, unscrew bolts -2-.

– Unbolt lock washers -3-.
– Thread out heat shield -1- and remove it.
– Guide out catalytic converter with front exhaust pipe between
body and assembly carrier.
Installing
served:
Note
♦ Renew seals/gaskets and self-locking nuts.

♦ Coat exhaust manifold studs with high-temperature paste;
high-temperature paste ⇒ Electronic parts catalogue .


Torque settings
♦ ⇒ “1.1 Assembly overview - silencers”, page 337
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion .

28 – Ignition system
1 Ignition system
page 349
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 352
⇒ “1.4 Removing and installing Hall sender”, page 352
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
353
1.1 Assembly overview - ignition system
1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 20 Nm
2 - Knock sensor 1 - G61-
stalling knock sensor 1
G61 ”, page 352
3 - Spark plug
❑ Remove and install with
spark plug socket and
extension - 3122 B-
❑ Specified torque: 22 Nm
❑ Change interval ⇒
Maintenance tables
❑ Part numbers ⇒ Elec‐
tronic parts catalogue
(ETKA)
4 - Ignition coil with output
stage and spark plug connec‐
tors
Note
Ignition coils with output stage and

spark plug connectors are available
individually for repairs ⇒ Electronic
parts catalogue (ETKA)
♦ Ignition coil 1 with output

stage - N70-
♦ Ignition coil 2 with output
stage - N127-
348 Rep. gr.28 - Ignition system

5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
8 - O-ring
9 - Bolt
❑ 8 Nm
11 - O-ring
12 - Sender wheel
❑ For engine speed sender - G28-
13 - Sealing flange, gearbox side
14 - Engine speed sender - G28-
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 353
15 - Bolt
❑ 4.5 Nm
1.2 Removing and installing ignition coils

with output stage
♦ Puller - T10530-
1. Ignition system 349

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 catalogue
(ETKA)
Removing
Overview of fitting locations
page 291 .
Assembly overview - ignition system
⇒ “1.1 Assembly overview - ignition system”, page 348 .
Removing ignition coils “cyl. 2, 3, 4”:
309 .
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 on puller - T10530- in -direction of arrow- out

of cylinder head cover.
Note
♦ Ignition coils with output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
(ETKA)
♦ The spark plug connectors are removed from the ignition coils
by hand.
Installing
served:
– Apply a thin bead of silicone paste around sealing hose of ig‐

nition coil ⇒ Electronic parts catalogue (ETKA) .
– Slide spark plug connector -1- by hand onto ignition coil as far
as stop.
The vent drilling -2- must be centred relative to connector housing

-3- while doing so.
– Insert all ignition coils loosely into spark plug hole.
– 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).
Torque settings

1.3 Removing and installing knock sensor 1

- G61-
Removing
page 291 .
Vehicles with air conditioner compressor:
CAUTION

– Disconnect electrical connector on air conditioner compressor
regulating valve - N280- .
nected from engine ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor; Removing air conditioner com‐
pressor from and installing to bracket .
nected, and tie it up on the right side.
– Unscrew bolt -2- and remove knock sensor 1 - G61- .
Installing
served:
– Install air conditioner compressor ⇒ Rep. gr. 87 ; Air condi‐
tioner compressor; Removing and installing air conditioner
compressor .
Torque settings
1.4 Removing and installing Hall sender

⇒ “1.4.1 Removing and installing Hall sender G40 ”, page 352
⇒ “1.4.2 Removing and installing Hall sender 3 G300 ”,
page 353
1.4.1 Removing and installing Hall sender -

G40-
Removing
page 291 .


309 .
– Unscrew bolt -2- and remove Hall sender - G40- .
Installing
– Install in reverse order of removal. The following should be
observed:
Specified torques
1.4.2 Removing and installing Hall sender 3 -

G300-
Removing
page 291 .
309 .
– Unscrew bolt -2- and remove Hall sender 3 - G300- .
Installing
– Install in reverse order of removal.
1.5 Removing and installing engine speed

sender - G28-
♦ Socket, 4 mm - T10370-

Removing
page 291 .
– Unscrew bolt -arrow- and push charge air cooling pump -
V188- to one side.

– Unscrew bolt -2- and remove engine speed sender - G28- .
Installing
– Install in reverse order of removal. The following should be
observed:
– Carefully insert the engine speed sender - G28- into the hole.
This will prevent the engine speed sender - G28- from falling
between engine and gearbox.
Torque settings
page 234

Engine Cpta Czca Czea Ea211 Eng

Uploaded by

Copyright:

Available Formats

Engine Cpta Czca Czea Ea211 Eng

Uploaded by

Document Information

Original Description:

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 Cpta Czca Czea Ea211 Eng

Uploaded by

Copyright:

Available Formats

What are the main sections covered in the workshop manual?

What are the main sections covered in the workshop manual?

What safety precautions should be observed when working on vehicles?

What safety precautions should be observed when working on vehicles?

Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.5 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

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 a 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 the vehicle data sticker ⇒ Maintenance ; Book‐

Engine code CPTA CZCA CZEA

Volkswagen Technical Site: http://vwts.ru http://vwts.info

3.1 Rules for cleanliness

3.2 Foreign objects in engine

3.3 Contact corrosion

3.4 Routing and attachment of lines

4 Rep. gr.00 - Technical data

3.5 Fitting radiator and condensers

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Release lever - 80 - 200-

6 Rep. gr.10 - Removing and installing engine

♦ Commercially available stepladder

♦ The engine is removed downwards together with the gearbox.

– Carefully open filler cap -1- on coolant expansion tank -2- in

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

Vehicles with manual gearbox

– If fitted, release and disconnect connector on vacuum sender

– Carefully loosen wiring harness at its fastening points

1. Removing and installing engine 7

– Release connector -arrow-, pull off and unclip from bracket.

– Attach protective mat - VAS 531003- to vehicle as shown in

– Remove poly V-belt

8 Rep. gr.10 - Removing and installing engine

Continued for all vehicles

– Detach exhaust hangers -3- in -direction of arrow- from sub‐

– Unscrew bolt -2-.

– Unscrew bolts -arrows- and remove bracket -1-.

1. Removing and installing engine 9

– Open spring-type clips -arrows-.

– Open spring-type clips -arrows-.

– Release retaining clips -arrows-.

10 Rep. gr.10 - Removing and installing engine

– Release and pull off connector -2- on starter -1-.

– Release and pull off connectors -2-.

– Release and pull off connector -3- on alternator -2-.