Engine Caxa CMSB Repair Manual Eng

Service
Workshop Manual
Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,
Passat 2006 ➤ , Passat 2011 ➤ ,
Passat Variant 2011 ➤ ,
Scirocco 2009 ➤ , Tiguan 2008 ➤
4-cyl. injection engine (1.4 l engine, 4V, EA 111,
turbocharger)
Engine ID
CAX CMS
A B
Edition 08.2018
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
20 - Fuel supply system
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg K0059101820

Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus ...
4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger) - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.6 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 15
2 Removing and installing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 Removing and installing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Assembly overview - parts l and ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Assembly overview - part I, belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.5 Removing and installing valve timing housing (Golf, Golf Plus, Eos, Scirocco) . . . . . . . . . . 52
1.6 Removing and installing valve timing housing (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.7 Removing and installing valve timing housing (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 68
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.5 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Contents i
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4.5 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 114
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.7 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.4 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Engine oil, oil capacities, engine oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Assembly overview (► model year 2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.3 Assembly overview (model year 2009 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.2 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 157
1.3 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.4 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5 Removing and installing radiator fan V7 and radiator fan 2 V177 (Golf, Golf Plus, Eos,
Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 (Tiguan, Passat) . . . . . . 163
1.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.8 Removing and installing radiator (Golf, Golf Plus, Scirocco, Eos) . . . . . . . . . . . . . . . . . . . . 165
1.9 Removing and installing radiator (Tiguan, Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.10 Removing and installing auxiliary radiator for charge air system (Tiguan, Passat) . . . . . . 169
1.11 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.12 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.2 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3 Fuel tank (Golf, Golf Plus, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
ii Contents
4 Fuel tank (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

5 Fuel tank (Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6 Fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.1 Assembly overview - fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.2 Draining fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.3 Removing and installing fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7 Repairing fuel supply system (Golf, Golf Plus, Scirocco, Eos) . . . . . . . . . . . . . . . . . . . . . . 213
7.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.2 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.3 Removing and installing fuel delivery unit (Golf Plus, Golf, Scirocco, Eos) . . . . . . . . . . . . 214
7.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
7.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8 Repairing fuel supply (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
8.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
8.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
8.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
9 Repairing fuel supply (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.3 Removing and installing fuel delivery unit (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
9.4 Removing and installing fuel gauge sender G (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.5 Removing and installing suction-jet pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.6 Removing and installing fuel gauge sender 2 G169 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 251
9.7 Removing and installing fuel pump control unit J538 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 251
9.8 Checking fuel pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10 Repairing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
10.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11 Activated charcoal filter system (Golf, Golf Plus, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . 264
11.1 Assembly overview (Golf, Golf Plus, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
11.2 Checking fuel tank breather (Golf, Golf Plus, Eos, Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . 265
12 Activated charcoal filter system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
12.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
13 Activated charcoal filter system (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
13.1 Assembly overview (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
13.2 Checking fuel tank breather (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1.2 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.3 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Contents iii
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

1.5 Removing and installing compressor housing and turbine housing . . . . . . . . . . . . . . . . . . 282
1.6 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.7 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.8 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
2.2 Removing and installing intake manifold charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . 298
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.1 Assembly overview - parts l and II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.2 Assembly overview - part I, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.3 Assembly overview - part II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.4 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
1.5 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
1.6 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.7 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
1.8 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
1.9 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
1.10 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.11 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.12 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1.13 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.14 Renewing Teflon seal and support washer on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.15 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
2 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
2.1 Removing and installing engine control unit J623 (Golf ► 2008, Eos) . . . . . . . . . . . . . . . . 328
2.2 Removing and installing anti-theft engine control unit J623 (Golf ► 2008, Eos ► 10.2008)
........................................................................ 329
2.3 Removing and installing engine control unit J623 (Golf 2009 ►) . . . . . . . . . . . . . . . . . . . . 331
2.4 Removing and installing anti-theft engine control unit J623 (Golf 2009 ►, Eos 11.2008 ►,
Scirocco 10.2008►, Passat 2011►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
2.5 Removing and installing engine control unit J623 (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . 335
2.6 Removing and installing anti-theft engine control unit J623 (Golf Plus) . . . . . . . . . . . . . . . . 336
2.7 Removing and installing engine control unit J623 (Passat 2006 ►) . . . . . . . . . . . . . . . . . . 339
2.8 Removing and installing anti-theft engine control unit J623 (Passat 2006 ►) . . . . . . . . . . 340
2.9 Removing and installing engine control unit J623 (Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . 341
2.10 Removing and installing anti-theft engine control unit J623 (Scirocco ► 09.2008) . . . . . . . . 342
2.11 Removing and installing engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 344
2.12 Removing and installing anti-theft engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . 345
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.1 Assembly overview - catalytic converter and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.2 Assembly overview - silencer with mountings (Golf, Golf Plus, Scirocco) . . . . . . . . . . . . . . 351
1.3 Assembly overview - silencer with mountings (Passat 2006 ►) . . . . . . . . . . . . . . . . . . . . . . 352
1.4 Assembly overview - silencer with mountings (Passat 2011 ►) . . . . . . . . . . . . . . . . . . . . . . 353
1.5 Assembly overview - silencer with mountings (Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.6 Assembly overview - silencer with mountings (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.7 Removing and installing centre and rear silencers (Golf, Golf Plus, Scirocco, Eos) . . . . . . 355
1.8 Detaching centre and rear silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.9 Detaching centre and rear silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
1.10 Installation position and specified torque of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
iv Contents
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 363
1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Contents v
vi Contents
00 – Technical data
1 Technical data
(VRL012112; Edition 08.2018)
Engine number ⇒ page 1
Engine data ⇒ page 1
1.1 Engine number

– Detach hose from activated charcoal filter at hose clip
-arrow-.
Engine code and engine number can be found on the sticker

-arrow- on the control housing.
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”. If
more than 999,999 engines were produced with the same code
letters, 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 and depends on
the engine control unit - J623- . The four-digit engine code can be
found on the type plate, the vehicle data label and on the engine
control unit.
Note
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

Vehicle data sticker
1.2 Engine data

Engine code CAXA
Manufactured
Golf 2004► 07.07►
Golf Plus 2005► 07.07►
Passat 2006► 11.07►
Eos 2006► (to 10.09 11.07►
EU4)
Exhaust emission standard EU4
1. Technical data 1
Engine code CAXA

Displacement cm3 1390
Power kW at rpm 90/5000
Torque Nm at rpm 200/1500-4000
Bore ∅ mm 76.5
Stroke mm 75.6
Compression ratio 10
RON min. 95 unleaded
Injection, ignition Motronic MED 17
Firing order 1-3-4-2
Type of mixture formation Homogeneous
Charging Exhaust turbocharger
Engine code CAXA CMSB

Manufactured
Golf 2009► 07.08► ---
Golf Plus 2009► 02.09► ---
Scirocco 2009► 11.08► 06.11►
Eos 2006► (from 11.07► ---
11.09 EU5)
Tiguan 2008► 07.10► ---
Passat 2006► 11.07► ---
Passat 2011► 11.10► ---
Exhaust emission EU5 EU4
standard
Displacement cm3 1390 1390
Power kW at rpm 90/5000 90/5000
Torque Nm at rpm 200/1500-4000 200/1500-4000
Bore ∅ mm 76.5 76.5
Stroke mm 75.6 75.6
Compression ratio 10 10
RON min. 95 unleaded 95 unleaded
Injection, ignition Motronic MED 17 Motronic MED 17
Firing order 1-3-4-2 1-3-4-2
Type of mixture formation Homogeneous Homogeneous
Charging Exhaust turbocharger Exhaust turbocharger
2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Removing and installing engine
(Golf, Golf Plus, Eos, Scirocco)
Removing engine ⇒ page 3 .
Securing engine to assembly stand ⇒ page 11 .
Installing engine ⇒ page 11 .
Specified torques ⇒ page 14
Assembly mountings ⇒ page 14
Additional information and assembly work for vehicles with air
conditioner ⇒ page 15 .
1.1 Removing engine
Special tools and workshop

equipment required
♦ Engine support - T40075- with adapters /1, /2, /3

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
1. Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 3

♦ Engine and gearbox support - VAS 6095-

♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-

♦ Stepladder - VAS 5085-
♦ Torque wrench (40 … 200 Nm) - V.A.G. 1332-
♦ Guide pins - T10093-
Note
The battery earth must be disconnected for the remaining proce‐

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.
4 Rep. gr.10 - Removing and installing engine

– Remove securing bolts -1- of engine cover panel.

– Detach coolant hoses -2- on engine cover panel and pull en‐
gine cover panel upwards.
– Remove air filter ⇒ page 305 .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 159 .
– Observe rules for cleanliness ⇒ page 213 .
– Separate fuel supply line -1- and line to activated charcoal filter
-2-.
– Separate plug-in connectors ⇒ page 180 .
WARNING
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.
Golf, Golf Plus, Eos, Scirocco
– Remove hose -3- from activated charcoal filter system sole‐

noid valve 1 - N80- to activated charcoal filter.
– Pull activated charcoal filter upwards and remove securing
bolts -arrows- from bracket.
Continued for all vehicles
– Remove coolant hoses -4-.
– Release coolant hoses -1- and -2- at radiator and pull them
off.

– Release coolant hoses at heat exchanger -arrows- and pull

them off.
– Unscrew securing bolts -arrows- and remove heat shield from

turbocharger.
– Unbolt securing nuts at turbocharger -arrows-.
– Remove securing bolts -arrows- of engine splash protection.

– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .

– Release coolant hose -1- at auxiliary radiator for charge air

system and remove coolant pipe -2-.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– If an auxiliary heater is fitted, remove coolant pipes -2-.
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Unclip wiring -1- from catalytic converter.
– Disconnect connectors -2-.

– Unscrew securing nuts -3- and remove seal.
– Remove catalytic converter downwards.
– Unbolt exhaust pipe together with flexible joint -arrows-.

– Loosen securing bolts of double clamp -arrows- and pull ex‐

haust pipe to rear.
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Pull vacuum and breather hoses off engine.
– Pull connectors off thermal switch and radiator fan.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Remove engine control unit ⇒ page 328 .
– Open all line guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.

– Disconnect pendulum support -arrows-.

Vehicles with manual gearbox
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism .
Note
Do not depress clutch pedal.
– Remove right drive shaft, and unscrew left drive shaft from
gearbox and tie up: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
Vehicles with automatic gearbox
– Remove selector lever cable ⇒ 7-speed dual clutch gearbox
0AM; Rep. gr. 34 ; Removing and installing selector lever ca‐
ble .
– Removing both drive shafts ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .
– Disconnect connector -1- from coolant circulation pump -
V50- .
– Detach spring-type clips -2- and pull coolant hoses off.

– Unscrew securing bolt -3- and remove pump from bracket.
– Remove bracket for coolant circulation pump - V50- from

crankcase -arrows-.
– Remove poly V-belt ⇒ page 51 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87
Note
The air conditioning system lines must not be opened.
– Secure air conditioner compressor to lock carrier.

– Ensure that lines are not kinked.
– Observe additional information and installation work
⇒ page 15 .

Engine support - T40075- with adapters -/1-, -/2- and -/3- is re‐
quired to lower engine with gearbox.
– Screw adapter - T40075/1- to stop into crankcase.

– Position the engine support - T40075- with adapters -/2- and
-/3- on crankcase.
– Insert 2 x M10 nuts between crankcase and engine support -
T40075- .
– Secure engine support - T40075- hand-tight to crankcase us‐

ing an M8×35 bolt -1-.
– Tighten all bolts on engine support - T40075- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

– Unbolt engine side of assembly mounting from above

-arrows-.
– Unbolt gearbox side of assembly mounting from above

-arrows-.
Note
To remove securing bolts use a stepladder - VAS 5085- .
– Carefully lower engine and gearbox.
1.2 Securing engine to assembly stand

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
Procedure
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .
1.3 Installing engine

Installation is carried out in the reverse order. When installing,
note the following:
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.
– Check clutch release bearing for wear and renew if necessary

(vehicles with manual gearbox).
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100 (vehicles with
manual gearbox).
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
Align engine mountings as follows:

♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that edges of support arm on gearbox assembly
mounting -2- and gearbox support -1- are parallel.
– Install pendulum support.
Note
Specified torques for assembly mountings ⇒ page 14 .

– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 02S; Rep. gr. 30 ; Repairing clutch mechanism .
– Install selector mechanism ⇒ 6-speed manual gearbox 02S;
Rep. gr. 34 ; Repairing selector mechanism .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
shafts .
– Installing selector lever cable ⇒ 7-speed dual clutch gearbox
0AM; Rep. gr. 34 ; Removing and installing selector lever ca‐
ble .
shafts .
– Install air conditioning system compressor ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 51 .
– Install catalytic converter and exhaust pipe.
Specified torques for exhaust system: ⇒ page 348
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Install engine splash protection.
– Add coolant ⇒ page 159 .
– Install air filter ⇒ page 305 .
– Install battery and battery carrier ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
– Connect ⇒ vehicle diagnostic tester .
– Erase learnt values, and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out vehicle system test: ⇒ Vehicle diagnostic tester
“Guided fault finding”.
– Finish the vehicle system test so that any event memory en‐
tries stored during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.

– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.4 Torque settings

Bolted connection Torque setting
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Note
1.5 Assembly mountings

Torque settings
Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° further
B 1) = 40 Nm + 90° further
C 1) = 60 Nm + 90° further
1) Renew
Gearbox mounting
A 1) = 40 Nm + 90° further
B 1) = 60 Nm + 90° further
1) Renew

Pendulum support
A 1) = property class 8.8 = 40 Nm + 90° (1/4 turn) further
B 1) = 100 Nm + 90° (1/4 turn) further
1) Renew
1.6 Additional information and assembly

work for vehicles with air conditioner
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.
sition .
ing system; Rep. gr. 87 .

2 Removing and installing engine (Ti‐

guan)
2.1 Removing engine

equipment required
♦ Engine support - T40075 A- with adapters /4, /5, /6

♦ Torque wrench - V.A.G 1331-

Note
The engine support - T40075- can continue to be used if conver‐

ted as described in the respective work sequence.
Converting engine support - T40075-

– Mark dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill hole through the material with 13.0 mm bit.
– Mark engine support after the tool designation with an -A-.
2. Removing and installing engine (Tiguan) 17


Note

dure. Check whether a coded radio is fitted. Then obtain anti-theft
coding first if necessary.
– Remove noise insulation or skid plate ⇒ General body repairs,

exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .
– Remove transverse member -1- by undoing the bolts
-arrows-.
– Unscrew bolts -1- securing engine cover panel.

– Pull out oil dipstick.
– Detach coolant hoses -2- from engine cover panel and pull
engine cover panel upwards.
cooling system.
WARNING
protective gloves to avoid injuries and skin contact. Wrap a
cloth around the connection before loosening hose connec‐
tions. Then release pressure by carefully pulling hose off con‐
nection.
– Detach fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing the release tabs.

– Release and pull coolant hoses -2- and -3- off radiator.
– Pull off coolant hose -1-, first releasing the retaining clip
-arrow-.

– Release coolant hoses and pull them off heat exchanger

-arrows-.
– Undo bolts -arrows- and remove heat shield from turbocharg‐

er.
– Undo nuts securing turbocharger -arrows-.

system and pull hose off.
– Remove coolant pipe -2-.

– Release connector -1- and pull it off oil level and oil tempera‐
ture sender - G266- .
Vehicles with auxiliary heater
– Remove coolant pipes -2-.
exterior; Rep. gr. 50 ; Front body: Lock carrier - service posi‐
tion .
– Unclip lines -1- at catalytic converter.

– Release connectors -2- and pull them off.
– Undo nuts -3- and remove seal.
Caution
Risk of damage to decoupling element.

♦ Do not allow the flexible joint to kink by more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
– Unscrew exhaust pipe together with decoupling element

-arrows-.

– Undo bolts -arrows- of double clamp and pull exhaust pipe to‐
wards the rear.
– All cable ties which are opened or cut through when engine is
removed must be fastened in the same position when engine
is installed.
– Release and detach connectors from coolant temperature
sender at radiator outlet - G83- , from radiator fan - V7- , and
from radiator fan 2 - V177- s.
– Open cable guide fasteners -arrows-.

– Remove cable from engine control unit.
– Secure cables to engine with cable tie.


– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 0BB; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed
manual gearbox 0BB; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .
Note
– Remove right drive shaft, and unscrew left drive shaft from
gearbox and tie up: ⇒ Running gear, axles, steering; Rep. gr.
shafts .
– Remove selector lever cable ⇒ Automatic gearbox 09M; Rep.
gr. 34 ; Removing and installing selector lever cable .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .

– Release and pull connector -1- off coolant circulation pump -
V50- .
– Release spring-type clips -2- and pull coolant hoses off.
– Undo bolt -3- and remove pump from bracket.

crankcase -arrows-.
Vehicles with air conditioning system
ing; Rep. gr. 87
Note

– Make sure lines are not kinked.
⇒ page 29 .

Use engine support - T40075A- with adapters -/4-, -/5- and -/6- to
lower engine with gearbox.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Insert two M10 nuts between crankcase and engine support -
T40075A- .
– Secure engine support - T40075A- hand-tight to crankcase

using an M8x35 bolt -1-.
– Tighten bolts attached to engine support - T40075A- to 20 Nm.

- V.A.G 1383 A- .


-arrows-.

-arrows-.
Note
To remove securing bolts use a stepladder - VAS 5085- .

carry out repairs.
Procedure
– Unbolt gearbox.

Install in reverse order of removal. During this procedure, observe
the following:
Caution
When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure clearance between lines and moving or hot com‐
ponents.

– Check clutch release bearing for wear and renew if necessary.
sleeve and splines on input shaft with G 000 100.



♦ On gearbox side, ensure that edges of support arm -1- and
gearbox bracket -2- are parallel.
Note


– Install hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed
manual gearbox 0BB; Rep. gr. 30 ; Repairing clutch mecha‐
nism .
– Attach selector mechanism ⇒ 6-speed manual gearbox 0BB;
Rep. gr. 34 ; Repairing selector mechanism .
shafts .
– Install selector lever cable: ⇒ Automatic gearbox 09M; Rep.
gr. 34 ; Removing and installing selector lever cable
shafts .
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 .
gr. 97 .
– Install noise insulation or skid plate ⇒ General body repairs,
or skid plate .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
– Perform vehicle system test ⇒ vehicle diagnostic tester “Gui‐
ded Fault Finding”.
– Finish vehicle system test; any fault entries recorded in the
memory during assembly will be deleted automatically.
Observe applicable safety measures when carrying out a road
test.
– Carry out road test.
– Perform vehicle system test and rectify any faults found.
2.4 Torque settings



M8 20 Nm
M10 45 Nm
M12 60 Nm
Note

Torque settings
Note

Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
Gearbox mounting
A 1) = 60 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further

1) Renew
Pendulum support
A Bolt M10 1) = 50 Nm + 90° (1/4 turn) further
A Bolt M12 1) = 60 Nm + 90° (1/4 turn) further
B Bolt M10 1) = 50 Nm + 90° (1/4 turn) further
B Bolt M12 1) = 60 Nm + 90° (1/4 turn) further
C 1) = 100 Nm + 90° (1/4 turn) further

1) Renew


Note
Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.

frigerant circuit:
tion .
ing; Rep. gr. 87

3 Removing and installing engine (Pas‐

sat)
3.1 Removing engine

equipment required


Note
♦ Crankcases were installed with different size threaded holes.

♦ Before installation, take note of these holes and use the ap‐
propriate engine support.
♦ The engine support - T40075- can continue to be used if con‐
verted as described in the respective work sequence.
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
work sequence ⇒ page 38 .
Converting engine support - T40075-

– Mark dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill hole through the material with 13.0 mm bit.
– Mark engine support after the tool designation with an -A-.
3. Removing and installing engine (Passat) 31


Note

dure. Check whether a coded radio is fitted. Then obtain anti-theft
coding first if necessary.

or skid plate .


– Remove intake air duct .
cooling system.
WARNING
protective gloves to avoid injuries and skin contact. Wrap a
cloth around the connection before loosening hose connec‐
tions. Then release pressure by carefully pulling hose off con‐
nection.
– Detach fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing the release tabs.
– Release and pull coolant hoses -2- and -3- off radiator.

– Pull off coolant hose -1-, first releasing the retaining clip
-arrow-.
– Release coolant hoses and pull them off heat exchanger

-arrows-.
– Undo bolts -arrows- and remove heat shield from turbocharg‐

er.

– Undo nuts securing turbocharger -arrows-.

system and pull hose off.
– Remove coolant pipe -2-.
– Release connector -1- and pull it off oil level and oil tempera‐
ture sender - G266- .
Vehicles with auxiliary heater
– Remove coolant pipes -2-.
Vehicles up to 10.2010
tion .
Vehicles from 11.2010

– Undo and remove bolts -arrows- of cowling.
– Release connectors -1- and pull off.
– Remove cowling downwards.


– Unclip lines -1- at catalytic converter.
– Release connectors -2- and pull them off.
– Undo nuts -3- and remove seal.
Caution
Risk of damage to decoupling element.

♦ Do not allow the flexible joint to kink by more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
– Unscrew exhaust pipe together with decoupling element

-arrows-.
– Undo bolts -arrows- of double clamp and pull exhaust pipe to‐
wards the rear.
– All cable ties which are opened or cut through when engine is
removed must be fastened in the same position when engine
is installed.
– Release and detach connectors from coolant temperature
sender at radiator outlet - G83- , from radiator fan - V7- , and
from radiator fan 2 - V177- s.

– Open cable guide fasteners -arrows-.

– Remove cable from engine control unit.
– Secure cables to engine with cable tie.

– Unbolt selector mechanism from gearbox: ⇒ Rep. gr. 34 ;
Repairing selector mechanism
– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;
Repairing clutch mechanism
Note
– Remove right drive shaft, unscrew left drive shaft at gearbox

and tie up ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing drive shafts; Removing and installing drive shafts
– Remove selector lever cable ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .

– Release and pull connector -1- off coolant circulation pump -
V50- .
– Release spring-type clips -2- and pull coolant hoses off.


crankcase -arrows-.
ing; Rep. gr. 87
Note

– Make sure lines are not kinked.
⇒ page 45 .
Note
♦ Crankcases were installed with different size threaded holes.

♦ Before installation, take note of these holes and use the ap‐
propriate engine support.
♦ The engine support - T40075- can continue to be used when
work has been done on it ⇒ page 31 .
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
work sequence.
Attachment of engine support - T40075A- to crankcase
Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
T40075A- .

– Secure engine support - T40075A- hand-tight to crankcase

using an M8x35 bolt -1-.
– Tighten bolts attached to engine support - T40075A- to 20 Nm.

- V.A.G 1383 A- .
Attachment of engine support - T40075- to crankcase

Engine support - T40075- with adapters -/1-, -/2- and -/3- is re‐

– Position the engine support - T40075- with adapters -/2- and
-/3- on crankcase.
T40075- .

– Secure engine support - T40075- hand-tight to crankcase us‐

ing an M8x35 bolt -1-.
– Tighten bolts attached to engine support - T40075- to 20 Nm.

- V.A.G 1383 A- .
Note
♦ To remove securing bolts of assembly mountings, use a step‐

ladder - VAS 5085- .
♦ Take different mountings of gearbox into account.

-arrows-.
Assembly mountings on the gearbox side with 2 bolts at gearbox

-arrows-.

Assembly mountings on the gearbox side with 3 bolts at gearbox

-arrows-.
Note
When lifted out, the engine/gearbox assembly must be carefully

guided to prevent damage to the bodywork.

carry out repairs.
Procedure
– Unbolt gearbox.

the following:
Caution
When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure clearance between lines and moving or hot com‐
ponents.

– Check clutch release bearing for wear and renew if necessary
(vehicles with manual gearbox).
sleeve and splines on input shaft with G 000 100 (vehicles with
manual gearbox).


– Bolt on gearbox.
Align engine mountings as follows

Align gearbox mountings as follows in the case of a gearbox

brackets with 2 bolts on the gearbox
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel.

Align gearbox mounting as follows if gearbox bracket is secured

to gearbox by three bolts.
♦ Ensure that edges of support arm -2- and gearbox bracket
-1- are parallel.
Note

– Install slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ; Re‐
pairing clutch mechanism .
– Mount selector mechanism: ⇒ Rep. gr. 34 ; Repairing selector
mechanism .
shafts .
– Install selector lever cable: ⇒ Automatic gearbox 09M; Rep.
gr. 34 ; Removing and installing selector lever cable
shafts .
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 .
gr. 97 .
or skid plate .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
– Perform vehicle system test ⇒ vehicle diagnostic tester “Gui‐
ded Fault Finding”.
– Finish vehicle system test; any fault entries recorded in the
memory during assembly will be deleted automatically.

Observe applicable safety measures when carrying out a road

test.
– Carry out road test.
– Perform vehicle system test and rectify any faults found.
3.4 Torque settings

M8 20 Nm
M10 45 Nm
M12 60 Nm
Note

Torque settings
Note

Engine mounting
A 1) = 20 Nm + 90° further
B 1) = 40 Nm + 90° further
C 1) = 60 Nm + 90° further
1) Renew
Gearbox mounting
A 1) = 40 Nm + 90° further
B 1) = 60 Nm + 90° further
1) Renew

Pendulum support
B 1) = 100 Nm + 90° (1/4 turn) further
1) Renew

Note


frigerant circuit
Vehicles up to 10.2010
tion .
Vehicles from 11.2010
ing; Rep. gr. 87

13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
♦ All bearing and running surfaces must be oiled before assem‐
bly.
Assembly overview - parts l and ll ⇒ page 46 .

Assembly overview - part I, belt drive ⇒ page 48 .
Assembly overview - part II, cylinder block ⇒ page 49 .
Removing and installing poly V-belt ⇒ page 51
Removing and installing valve timing housing (Golf, Golf Plus,
Eos, Scirocco) ⇒ page 52
Removing and installing valve timing housing (Tiguan)
⇒ page 57 .
Removing and installing valve timing housing (Passat)
⇒ page 61 .
Removing and installing ancillary bracket ⇒ page 66 .
Note

carry out repairs.
1.1 Assembly overview - parts l and ll
46 Rep. gr.13 - Crankshaft group

1. Dismantling and assembling engine 47

1.2 Assembly overview - part I, belt drive
1 - 20 Nm
2 - Pulley
❑ For coolant pump
❑ Use water pump wrench
- V.A.G 1590- to loosen
and tighten.
3 - 40 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Removing and installing
with vehicle raised
4 - 40 Nm
5 - Washer
6 - Idler roller
7 - Washer
8 - Spacer sleeve
9 - Alternator
10 - 25 Nm
11 - Centring sleeve
12 - Tensioning element
13 - Pulley
❑ For crankshaft
❑ Contact surfaces must
be free of oil and grease.
14 - 150 Nm + 1/2 turn (180°)
further
❑ Note tightening se‐
quence ⇒ page 72 .
❑ Renew
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure belt pulley against turning with counterhold - 3415- .
❑ Turning further can be done in several stages.
❑ The turning further angle can be measured with a commercial protractor.

1.3 Assembly overview - part II, cylinder block
1 - Cylinder head with cam‐

shaft housing
⇒ page 128
❑ Do not rework sealing
surface.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant resi‐
due.
❑ Coat with
AMV 188 001 02 before
fitting.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block
⇒ page 68 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 88
3 - Ancillary bracket
❑ For tensioning element
and air conditioner com‐
pressor
⇒ page 66
4 - Cover
5 - Sprocket
❑ For oil pump drive and
timing chain.
❑ Contact surfaces must be free of oil and grease.
6 - 20 Nm + 1/4 turn (90°) further
❑ Renew
7 - Sprocket
❑ Lock sprocket using counterhold tool -T10172- .
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - 25 Nm
10 - Locating pin for chain tensioner
❑ Specified torque: 8 Nm
11 - Chain tensioner with tensioning rail
❑ For oil pump drive.
12 - Spring
13 - Sump
❑ Removing and installing ⇒ page 146

❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 404 A2
14 - 13 Nm
❑ Renew
15 - Piston
❑ For drive chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve timing housing
❑ Removing and installing, Golf, Golf Plus, Scirocco, Eos
⇒ “1.5 Removing and installing valve timing housing (Golf, Golf Plus, Eos, Scirocco)”, page 52
❑ Removing and installing, Tiguan
⇒ “1.6 Removing and installing valve timing housing (Tiguan)”, page 57
❑ Removing and installing, Passat
⇒ “1.7 Removing and installing valve timing housing (Passat)”, page 61
❑ Install with sealant D 176 501 A1.
❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide
❑ For better guidance of valve timing housing, secure sump in position with 2 bolts.
20 - 10 Nm
21 - Pulley
❑ Note tightening sequence ⇒ page 72 .
❑ Removing and installing poly V-belt ⇒ page 51
22 - 150 Nm + 1/2 turn (180°) further
❑ Removing and installing crankshaft pulley ⇒ page 72
❑ Renew
23 - Bearing bush
24 - O-ring
❑ Renew
25 - 50 Nm
26 - Seal
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ Renew
28 - 50 Nm + 1/4 turn (90°) further
❑ Renew

29 - Tensioning rail
30 - Camshaft adjuster
❑ Must not be dismantled.
31 - Timing chain
32 - Sprocket
❑ For exhaust camshaft
❑ Lock sprockets using counterhold -T10172- .
33 - Slide rail
❑ For timing chain
34 - Guide pin
35 - Bearing bush
1.4 Removing and installing poly-V belt

Special tools and workshop equipment required
♦ 16 mm spanner
Removing
or skid plate .
– Mark direction of rotation of poly V-belt.
– Swing poly V-belt tensioning element with a 16 mm spanner
in -direction of arrow- to slacken belt.
– Lock tensioning element with a 4 mm Allen key -1-.
– Remove poly V-belt.
Installing
– First fit poly V-belt onto vibration dampers. Finally, push belt
onto tensioning roller.
Further assembly is basically a reverse of the dismantling se‐
quence.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When fitting the poly V-belt observe belt direction of rotation
and that the belt is seated correctly in the belt pulleys.
On completing work:
– Start engine, and check if belt runs properly.

1.4.1 Poly V-belt routing

Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Idler roller
3 - Alternator pulley
4 - Tensioning pulley
5 - Air conditioner compressor pulley
6 - Crankshaft pulley
Belt drive without air conditioner compressor

1 - Pulley - cooling system pump
2 - Tensioning pulley
3 - Alternator pulley
4 - Poly V-belt
5 - Crankshaft pulley
1.5 Removing and installing valve timing housing (Golf, Golf Plus, Eos, Sciroc‐
co)


equipment required
♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /8-
♦ Counter-hold tool - 3415-
♦ Pin - 3415/1-
♦ Torque wrench (40 to 200 Nm) - V.A.G. 1332-
♦ Sealant D 176 501 A1

1.5.1 Removing
– Remove engine splash protection.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ page 51 .
– Turn crankshaft in direction of engine rotation to TDC for no.
1 cylinder ⇒ page 97 .
– Remove coolant pump pulley ⇒ page 173 .
Vehicles from model year 2009 ►
– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Remove ancillary bracket.
– Remove alternator.
Scirocco
– Install support device - 10 - 222 A- with adapter - 10 - 222 A /

8- as shown and hook into lifting eye.
– Position adapter - 10 - 222 A /8- on vehicle front end
-arrows- as shown.
All vehicles

– Install support device - 10 - 222 A- with adapter - 10 - 222 A /

8- as shown and hook into lifting eye.
– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump ⇒ page 146 .
– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .
– Remove bracket -1- by undoing the bolts -arrows-.

– Remove Allen head bolts for valve timing housing and hexa‐
gon bolts indicated by -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.
1.5.2 Installing
Note
Note that belt pulley contact surfaces, securing bolt, bearing bush
and crankshaft sprocket must be free of oil and grease.
– Clean sealing surfaces carefully. They must be free of oil and

grease.
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.
♦ Do not apply sealant until directly before the valve timing
housing is fitted.

– Apply sealant D 176 501 A1 to the joints camshaft housing/

cylinder head -1- and cylinder head/cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that valve timing housing is not canted.
Specified torque:
M6 bolt to 10 Nm
M8 bolt to 20 Nm
M10 bolt to 50 Nm
Engine mountings ⇒ page 14

Install crankshaft belt pulley ⇒ page 72 .
quence.
1.6 Removing and installing valve timing housing (Tiguan)


equipment required
♦ Adapter - 10 - 222 A /22-
♦ Pin - 3415/1-
♦ Sealant - D 176 501 A1-
Removing


or skid plate .
– Remove front right wheel housing liner: ⇒ General body re‐
housing liner .
– Mark running direction of poly V-belt.
– Turn crankshaft in engine direction of rotation to TDC for No.
– Remove poly V-belt of coolant pump ⇒ page 173 .
– Remove banjo bolt of oil supply pipe for turbocharger.
– Remove bracket for ancillaries ⇒ page 66 .
– Support bracket - 10 - 222 A- with adapter - 10 - 222 A /22-

-arrows-.
– Undo bolt for poly V-belt. Hold pulley with counterhold - 3415-
and -3415/1- .

– Undo socket bolts of valve timing housing.

– Undo the marked socket bolts -arrows-.
Note
Installing
the following:
Note
The pulley contact surfaces, securing bolt, bearing bush and

crankshaft sprocket must be free of oil and grease.
Clean sealing surfaces carefully.

The sealing surfaces must be free of oil and grease.
Note

of approx. 1 mm.
housing is fitted.


– Place new seal onto dowel pins.
– Screw two -M6x80- studs into cylinder head and cylinder block
to improve guidance.
– Fit timing housing with crankshaft bearing bush simultaneous‐
ly onto studs, dowel pins and crankshaft journal.
onally.
Ensure that timing housing is not canted.
Torque setting
M6 bolt to 10 Nm
M8 bolt to 20 Nm
M10 bolt to 50 Nm

1.7 Removing and installing valve timing housing (Passat)


equipment required
♦ Adapter - 10 - 222 A /22-
♦ Pin - 3415/1-
♦ Sealant - D 176 501 A1-
Removing


or skid plate .
housing liner .
– Mark running direction of poly V-belt.
– Remove poly V-belt of coolant pump ⇒ page 173 .
– Remove banjo bolt of oil supply pipe for turbocharger.
– Remove bracket for ancillaries ⇒ page 66 .
– Position support bracket - 10 - 222 A- with adapter - 10 - 222

A /8- and hook - 10 - 222 A /10- as shown in illustration.
– Fit adapter - 10 - 222 A /8- behind bolts -arrow 1- and
-arrow 2-.
WARNING
Do not position adapter - 10 - 222 A /8- on edges of wing.

The wing will otherwise be damaged.

-arrows-.

– Undo bolt for poly V-belt. Hold pulley with counterhold - 3415-
and -3415/1- .

– Undo socket bolts of valve timing housing.

– Undo the marked socket bolts -arrows-.
Note
Installing
the following:
Note
The pulley contact surfaces, securing bolt, bearing bush and

Clean sealing surfaces carefully.

The sealing surfaces must be free of oil and grease.
Note

of approx. 1 mm.
housing is fitted.

– Place new seal onto dowel pins.
– Screw two -M6x80- studs into cylinder head and cylinder block
to improve guidance.
– Fit timing housing with crankshaft bearing bush simultaneous‐
ly onto studs, dowel pins and crankshaft journal.
onally.
Ensure that timing housing is not canted.
Torque setting
M6 bolt to 10 Nm
M8 bolt to 20 Nm
M10 bolt to 50 Nm


1.8 Removing and installing bracket for an‐

cillaries
Removing
or skid plate .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
ing; Rep. gr. 87
Note


– Unscrew securing bolts -1- and remove bracket.

Installing
– Fit ancillary bracket to cylinder block.
– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 3 (page 48)
quence.

2 Removing and installing sealing

flanges and flywheel or drive plate
Assembly overview ⇒ page 68
Removing and installing engine speed sender - G28-
⇒ page 69 .
Renewing crankshaft oil seal on belt pulley end ⇒ page 70 .
Removing and installing crankshaft pulley ⇒ page 72
Renewing crankshaft sealing flange - flywheel end ⇒ page 75 .
2.1 Assembly overview
Note
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

installing clutch .
1 - 150 Nm + 1/2 turn (180°)

further
❑ Renew
crankshaft pulley
⇒ page 72
❑ Contact surface for se‐
curing bolt must be free
of oil and grease.
❑ Oil threads before in‐
serting.
❑ Secure pulley against
turning with counterhold
3415.
❑ The turning further an‐
gle can be measured
with a commercial pro‐
tractor.
2 - Pulley
❑ Secure against turning
with counterhold - 3415-
when removing and in‐
stalling
poly V-belt ⇒ page 51
3 - Seal
❑ Renew
4 - Bearing bush
5 - O-ring
❑ Renew
6 - Cylinder block

7 - 60 Nm + 1/4 turn (90°) further

❑ Renew
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
10 - 10 Nm
❑ Renew
11 - Sealing flange with sender wheel and oil seal
❑ Removing and installing engine speed sender - G28- (not shown) ⇒ page 69 .
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 75 .
2.2 Removing and installing engine speed

sender - G28-
♦ Torx bit - T10370-
Removing
Engine speed sender is located under intake manifold on sealing
flange on flywheel end of crankcase.
– Pull off connector -1- from engine speed sender - G28- .
– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installing
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
quence.
2. Removing and installing sealing flanges and flywheel or drive plate 69

2.3 Renewing crankshaft oil seal - belt pulley end

equipment required
♦ Seal puller - 3203-

♦ Assembly sleeve - T10117/2- from assembly tool - T10117A-
♦ Assembly tool - T10053-
Removing
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .

– Now remove pulley securing bolt. Hold pulley with counterhold

tool -3415- and -3415/1- .
– Unscrew inner part of oil seal extractor - 3203- 3 turns (approx.

5 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove bearing bush from crankshaft journal and clean con‐
tact surfaces of crankshaft sprocket and bearing bush.
Installing
Note
Note that pulley contact surfaces, securing bolt, bearing bush and
– Push bearing bush onto crankshaft journal.
– Fit sleeve -T10117/2- from assembly tool - T10117A- onto

bush, and push oil seal onto bush.
– Remove sleeve -T10117/2- from bush.
– Drive oil seal into valve timing housing to stop using assembly
tool -T10053- and striking evenly with a hammer.
quence.

2.4 Removing and installing crankshaft pulley

equipment required

♦ Pin - 3415/1- (not illustrated)
♦ Locating bolt - T10340-

♦ Dial gauge - VAS 6079-
♦ Dial gauge adapter - T10170-

Removing

– Loosen pulley securing bolt. Hold pulley with counterhold -

3415- and -3415/1- .
Installing
– Tighten pulley hand-tight using a new securing bolt.

– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
Note
♦ Note that all contact surfaces from the securing bolt to the
♦ Always use a new bolt.
Specified torque: 150 Nm + 1/2 turn (180°) further.

Hold pulley with counterhold - 3415- and -3415/1- .

– Unscrew locking pin - T10340- from crankcase.

– Screw plug into crankcase.
Specified torque: 30 Nm
quence.
2.5 Renewing crankshaft sealing flange - flywheel end


equipment required

♦ Tool insert 24 mm - V.A.G 1332/11-
♦ 3 hexagon bolts M6 x 35 mm
♦ Feeler gauge
♦ Depth gauge
2.5.1 Pressing sealing flange with sender

wheel off crankshaft
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
Procedure
– Remove flywheel or drive plate as applicable.

– Set engine to TDC No. 1 cylinder ⇒ page 97

– Remove engine speed sender - G28- -arrow-.
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together with 3 M6 × 35 mm bolts.
– Screw three M6×35 mm bolts into threaded holes -arrows- of

sealing flange.
– Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into
sealing flange and press sealing flange together with sender
wheel off crankshaft.
2.5.2 Pressing sealing flange with sender

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

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Do not separate or turn the sealing flange and sender wheel
after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

Assembly tool - T10134-

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
2.5.3 A - Assemble seal with sender wheel on

assembly tool - T10134- .
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.

– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.
– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
– Place sealing flange with front side on assembly tool - T10134-

so that locating pin -A- can be inserted in sender wheel hole
-A-.
Note
Ensure sealing flange lies flat on assembly tool.

– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.5.4 B - Attaching assembling tool - T10134-

with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.
– Screw hexagon nut -B- to end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase
sealing surface.
– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange, screw 2 M6 × 35 mm bolts -A- into

cylinder block.

2.5.5 C - Bolting assembly tool - T10134- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for petrol engines (red knob) -F- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
The guide pin for diesel engines (black knob) -D- must not be
inserted in threaded hole of crankshaft.
– Hand-tighten both hexagon socket head bolts of assembly

tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.
2.5.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
2.5.7 E - Checking sender wheel installation

position on crankshaft

♦ Ruler - T40100-

– Screw hexagon nut -E- to end of threaded spindle.

– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Unscrew the two hexagon socket-head bolts on the assembly
device again.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

– Measure the distance »a« between crankshaft flange and
sender wheel.
Note
If the engine and gearbox support - VAS 6095- does not provide
the necessary space, the ruler - T40100- should be placed on the
crankshaft flange and the distance determined with a feeler
gauge.
If dimension »a« is too small:

– Re-press sender wheel ⇒ page 83 .
If dimension »a« is achieved:
– Tighten new securing bolts for sealing flange to 10 Nm using
alternate and diagonal sequence.
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 146 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm +1/4 turn (90°).

2.5.8 f) Re-pressing sender wheel

– Secure assembly tool - T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 81 .
If dimension »a« is still too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 81 .

3 Crankshaft
Pulling needle bearing out of and driving into crankshaft
⇒ page 85 .
Crankshaft dimensions ⇒ page 87 .
1 - 50 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew
❑ Only tighten to 50 Nm
when measuring crank‐
shaft radial clearance.
Do not turn further.
2 - Bearing cap
❑ Do not interchange
bearing caps (mark po‐
sitions).
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Crankshaft
❑ Axial clearance (new):
0.07 … 0.24 mm
❑ Wear limit: 0.26 mm
Check radial clearance with
Plastigage
❑ New: 0.03 … 0.05 mm
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Pulling needle bearing
out of and driving into
crankshaft
⇒ page 85 .
❑ Crankshaft dimensions
⇒ page 87 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 75 .
5 - 10 Nm
❑ Renew
6 - Thrust washers
❑ For bearing cap 3

❑ Note fixing arrangement
7 - Bearing shell
❑ In cylinder block
8 - Sprocket
❑ For oil pump drive and timing chain.
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Pulling needle bearing out of and driving

into crankshaft
Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
♦ Drift - VW 207 C-
3. Crankshaft 85
Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Installing
Note
The needle bearing must always be renewed after the gearbox

has been separated from the engine.
Condition:
• 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.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .

Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐

box; Installing gearbox .
3.3 Crankshaft dimensions

Honing Crankshaft Conrod
dimension in mm main journal ∅ journal ∅
Basic dimension -0.022 -0.022
54.00 47.80
-0.037 -0.037
Stage I -0.022 -0.022
53.75 47.55
-0.037 -0.037
Stage II --- -0.022
47.30
-0.037
3. Crankshaft 87
4 Dismantling and assembling pistons

and conrods
Checking piston ⇒ page 90 .
Checking cylinder bores ⇒ page 91 .
Piston and cylinder dimensions ⇒ page 91 .
Removing and installing pistons ⇒ page 92 .
Removing and installing oil spray jets ⇒ page 93 .
Note
All bearing and running surfaces must be oiled before assembly.
1 - Retaining ring
2 - Piston pin
❑ If difficult to remove,
heat piston to 60°C.
❑ Remove and install us‐
ing drift - 10 - 14- .
3 - Piston
❑ Checking ⇒ page 90
❑ Mark installation posi‐
tion and cylinder num‐
ber.
Caution
Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring

clamp.
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 90 .
❑ Checking ring-to-groove
clearance ⇒ page 90 .
5 - Oil scraper rings
❑ Carefully remove and
install 3-part oil scraper
rings by hand.
❑ Checking ring gap ⇒ page 90 .
❑ Ring-to-groove clearance not measurable.

6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.
❑ M8×1: 30 Nm + 1/4 turn (90°) further.
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
8 - Bearing shell
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Checking radial clearance with Plastigage:
❑ New: 0.020 … 0.060 mm
❑ Do not rotate crankshaft when checking radial clearance.
9 - 27 Nm
❑ Opening pressure of pressure relief valve: 1.8 … 2.2 bar
10 - Oil spray jet
❑ For piston cooling.
11 - Connecting rod
❑ Renew as set only.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
❑ Separating new conrod ⇒ page 91 .
Caution
The conrod must be re‐
installed in exactly the
same position as it was
previously installed.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.
❑ Guided axially by piston.
4. Dismantling and assembling pistons and conrods 89

4.2 Checking piston

♦ External micrometer 75 - 100 mm - VAS 6071-
Checking piston
– Measure pistons approx 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter max. 0.04 mm. Nominal dimension
⇒ page 91
Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 … 0.40 1.0
2nd compression ring 0.40 … 0.60 1.0
Oil scraper ring 0.20 … 0.80 ---1)
1) No wear limit details available
Checking ring-to-groove clearance

Clean annular groove before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.04 … 0.08 0.15
2nd compression ring 0.02 … 0.06 0.15
Oil scraper ring Cannot be measured

4.2.1 Checking cylinder bores

♦ Cylinder gauge - VAS 6078-
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm.
– Nominal dimension ⇒ page 91
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
4.3 Separating new conrod

On a new conrod, it is possible that the breaking point has not
fully separated. If the conrod bearing cap cannot be removed by
hand, proceed as follows:
– Mark cylinder allocation of conrod ⇒ Item 11 (page 89)
– Gently clamp conrod, as shown in illustration, in a vice with
soft aluminium jaws.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.

♦ Conrod is clamped below the dashed line.
– Unscrew the two bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
4.4 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ 2) Cylinder bore ∅
sion
Basic dimen‐ mm 76.475 76.51
sion

Honing dimen‐ Piston ∅ 2) Cylinder bore ∅

sion
Stage III mm 76.495 76.53
2) Measure pistons approx. 12 mm from lower edge.
4.5 Removing and installing pistons

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

Removing
– Remove cylinder head ⇒ page 128 .
– Mark piston installation position and corresponding cylinder
number ⇒ Item 3 (page 88) .
– Mark conrod installation position and corresponding cylinder
and conrod bearing cap ⇒ Item 7 (page 89) .
– 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
Install in reverse order of removal, observing the following:
Note
Renew bolts that are tightened with turning further angle.
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ Item 3 (page 88) .
– Install conrod bearing cap, observing installation position
⇒ Item 7 (page 89) .
– Install cylinder head ⇒ page 128 .


Torque settings
♦ ⇒ “4.1 Assembly overview”, page 88
4.6 Removing and installing oil spray jets

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove oil pump ⇒ page 149 .
Note
♦ The crank web of the respective cylinder must be positioned

so that the socket - T10545- can be inserted in the pressure
relief valve as close to vertical as possible.
♦ 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
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.
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.
– Install oil pump ⇒ page 149 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head, all the contact

surfaces between the support elements, roller rocker arms
and the cams must be oiled before installing the camshaft
housing.
♦ Do not remove the plastic packing pieces for protecting the
open valves until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
♦ All bearing and running surfaces must be oiled before assem‐
bly.
♦ Removing and installing intake manifold ⇒ page 310 .

Checking valve timing ⇒ page 97 .
Adjusting valve timing ⇒ page 99
Checking timing chain ⇒ page 108
Removing and installing timing chain and drive chain for oil pump
⇒ page 114
Removing and installing camshaft housing ⇒ page 122 .
Removing and installing cylinder head ⇒ page 128 .
Checking compression ⇒ page 131 .
94 Rep. gr.15 - Cylinder head, valve gear

1 - 20 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
⇒ page 311
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
6 - Hall sender - G40-
❑ With O-ring
❑ Renew O-ring if dam‐
aged.
7 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
8 - Camshaft case
Caution
The studs (M6x80) must
be screwed into cylinder
head before installing
camshaft housing.
The camshaft housing is
guided by the studs, so
that the roller rocker fin‐
gers do not slip off the
supporting elements.

❑ Remove sealant residue.
❑ Carefully clean sealing surfaces. They must be oil and grease free.
❑ Coat with D 154 103 A1 before fitting
❑ When installing, fit vertically from above onto studs and dowel pins.
9 - 20 Nm
10 - Lifting eye
11 - Exhaust turbocharger
12 - Oil pressure switch - F1- , 20 Nm
❑ Remove and renew old seal ⇒ Electronic Parts Catalogue (ETKA)
13 - Cylinder head gasket
❑ Renew
❑ Metal gasket.
❑ After renewing, renew entire coolant.
1. Cylinder head 95
14 - Cylinder head
❑ Check for distortion ⇒ page 96 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
❑ After renewing, renew entire coolant.
15 - Guide pin
16 - Dowel pin
17 - Support element
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface
18 - Roller rocker fingers
❑ Check roller bearing for ease of movement.
❑ When installing, secure to supporting element using securing clip.
19 - Cylinder head bolt
❑ Renew
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 128 .
20 - Seal
Note
Note the different sealing types

when removing and installing the
camshaft housing ⇒ page 122 .
❑ Renew
❑ Qty. 4
❑ Inserted into cylinder head.
21 - Roller tappet
❑ Lightly coat contact surface with engine oil.
22 - O-ring
❑ Renew
❑ Moisten with oil before inserting.
Checking cylinder head for distortion

Check with straightedge 500 mm - VAS 6075- and feeler gauge.
Max. permissible distortion: 0.05 mm

1.2 Checking valve timing

equipment required
♦ Spark plug socket - 3122 B-

♦ Puller - T10094 A-
♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A-
♦ Camshaft clamp - T10171 B- (use new version)
Note
The mounting points for securing the camshaft clamp were modi‐
fied. A new special tool designated camshaft clamp - T10171 B-
has been introduced.
1. Cylinder head 97
Test sequence
– Remove lower part of front right wheel housing liner ⇒ General
– Drain coolant
⇒ “1.4 Draining and adding coolant”, page 159 .
– Unscrew securing bolts -1- of engine cover panel.
– Pull coolant hoses off coolant pipe -1- and unscrew coolant
pipe from camshaft housing and from cylinder block from be‐
low.
– Release connector -2- and pull off.
Note
Disregard item -1-.
– Then remove bolts for both camshaft covers -3-.
– Unclip engine pre-wiring harness -1-.

– Pull coolant pipe -2- and engine pre-wiring harness -1- away
from cylinder head.
– Lever off both camshaft covers -3- from cylinder head.
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B ⇒ page 363

– Screw dial gauge adapter -T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC for No.
1 cylinder. Note position of small needle on dial gauge.
The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.
Note
♦ If crankshaft is turned 0.01 mm passed TDC, turn crankshaft

two full turns in engine direction of rotation to set crankshaft at
TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
Caution
Before using camshaft clamp - T10171 B- you must check that

the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.
– Insert camshaft clamp -T10171 B- to stop in camshaft open‐

ings.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.
If camshaft clamp -T10171 B- cannot be fitted into camshaft
openings to stop, then timing is incorrect and must be readjusted
⇒ “1.3 Adjusting valve timing”, page 99 .
Timing is OK if camshaft clamp -T10171 B- can be fitted into
camshaft openings to stop.
If valve timing is not OK, adjust valve timing
quence. During this procedure, observe the following:
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
– Fill coolant system with coolant
1.3 Adjusting valve timing
1. Cylinder head 99

equipment required

A-
♦ Counter-hold tool - T10172-
♦ Pin - T40011-


♦ Locating bolt - T10340-
1. Cylinder head 101


Procedure
– Drain coolant
low.

Note
Disregard item -1-.

from cylinder head.
– Remove valve timing housing
⇒ “1.5 Removing and installing valve timing housing (Golf, Golf
Plus, Eos, Scirocco)”, page 52 .
– To turn crankshaft, reinstall bearing bush, crankshaft pulley

-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counterhold 3415).
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 363
– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge -VAS 6079- and extension -T10170/1- in to
– Then turn crankshaft 2 revolutions in engine direction of rota‐
tion.

– Press tensioning guide rail -1- in direction of arrow and lock

piston with locking pin -T40011- .
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Caution
Camshaft adjuster centre bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .
– Install camshaft adjuster -1- again.
– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt
-4- to 50 Nm (use counterhold -T10172- ).
Caution

be renewed.
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 B- can be pushed into holes in camshaft to stop.
Note
Do not push camshafts axially whilst turning.

– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 B- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 B- .
– Remove camshaft sprocket bolts. It is absolutely necessary to

use counterhold -T10172- for this.
Note
Do not use camshaft clamp - T10171 B- as a counterhold.
– Remove one camshaft sprocket.

– Place timing chain over camshaft sprockets, observing chain
direction of rotation, and install camshaft sprocket again.
– Tighten camshaft bolts until camshaft sprockets can still just
be turned on camshafts.
– Tension timing chain by removing locking pin - T40011- .

1 cylinder. Permissible deviation from TDC for No. 1 cylinder:
± 0.01 mm.
Note
If crankshaft is turned 0.01 mm passed TDC, turn crankshaft two

full turns in engine direction of rotation to set crankshaft at TDC
for No. 1 cylinder.

– Remove bolt -3- and detach continued coolant circulation
pump - V50- .

– Unscrew plug -arrow- from crankcase.

Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
– Hold camshaft sprockets -1- and -5- in this position with coun‐
terhold -T10172- then tighten bolt -2- (left-hand thread) to
40 Nm and bolt -4- to 50 Nm.
Note
Crankshaft cannot move, and timing chain -3- must remain ten‐
sioned on both sides when tightening camshaft bolts.
– Remove camshaft clamp -T10171 B- .
– Unscrew locking pin - T10340- from crankcase.

– Turn crankshaft 2 turns in direction of engine rotation to TDC
of No. 1 cylinder. Permissible deviation from TDC of No. 1 cyl‐
inder: ± 0.01 mm.
Caution

be renewed.

– Insert camshaft clamp -T10171 B- to stop in camshaft open‐

ings.
If camshaft clamp -T10171 B- cannot be fitted:
– Repeat adjustment.
If camshaft clamp -T10171 B- can be fitted


– Remove camshaft clamp -T10171 B- , hold camshaft sprock‐

ets with counterhold -T10172- and tighten bolts -2- (left-hand
thread) and -4- a 1/4 turn (90°) further with a rigid wrench.
Note
Camshaft adjuster centre bolt -2- has a left-hand thread.
Note
Camshaft sprockets cannot move on camshaft whilst tightening.

Note
The locking pin - T10340- remains in the crankcase until the

crankshaft pulley is installed.
♦ Install valve timing housing

⇒ “1 Dismantling and assembling engine”, page 46 .
♦ Install crankshaft pulley
⇒ “2.4 Removing and installing crankshaft pulley”, page 72 .
♦ Install poly V-belt
⇒ “1.4 Removing and installing poly-V belt”, page 51 .
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
♦ Specified torque for continued coolant circulation pump -
V50- : 10 Nm
♦ Fill coolant system with coolant
1.4 Checking timing chain

♦ Torque wrench - VAS 6583-

♦ Tester for checking elongation of chain links - T10550-
♦ Camshaft clamp - T10550/1-

♦ Indicator - T10550/2-
♦ Scale sleeve - T10550/3-
• The engine oil temperature must be at least 40°C ⇒ Vehicle
diagnostic tester.
• The engine must necessarily not be at »TDC« position.
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .
– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise
insulation; Assembly overview - noise insulation .
– Remove front right wheel housing liner: ⇒ General body re‐
housing liner .
– Remove poly V-belt
– Drain coolant
Vehicles with auxiliary/supplementary heater:
– Open hose clips, and pull coolant hoses off coolant pipes -1-.
– Remove auxiliary/supplementary heater with exhaust pipe
and coolant hoses still connected ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; auxiliary/supplementary heater;
Removing and installing auxiliary/supplementary heater .
Continued for all vehicles:


low.
Note
Disregard item -1-.
– Remove bolts for both camshaft covers -3-.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– Lever both camshaft covers -3- out of cylinder head.
– The hole in the left exhaust camshaft -left arrow- must be

positioned as shown in the illustration.
– If necessary, turn crankshaft in direction of engine rotation.

– Insert camshaft clamp - T10550/1- to stop in camshaft open‐

ings.
– The locking pin -arrow A- must engage in hole -arrow B- in
exhaust camshaft.
– Inscription “TOP” must be readable from above.
– Bolt on camshaft clamp - T10550/1- hand-tight.

– Use one bolt of the camshaft covers for this purpose -arrow-.
– Screw indicator - T10550/2- into hole in sump.

– Align centring point vertically so that the tip faces upwards.
– Tighten centring point with knurled nut.
– Position scale sleeve - T10550/3- on belt pulley.
Caution
There is a risk of injury caused by trapping fingers.

The scale sleeve - T10550/3- is equipped with magnets.
Proceed with great care when joining the components.
Note that the components are drawn together quickly by the
magnetic force.
– Align scale sleeve - T10550/3- with indicator - T10550/2- as

shown in illustration.

– Apply torque wrench - VAS 6583- with a suitable socket to

crankshaft bolt.
– Push torque wrench - VAS 6583- clockwise and maintain a
torque of 40 Nm on it.
– Set scale sleeve - T10550/3- and indicator - T10550/2- to »0«.

– Switch setting of torque wrench - VAS 6583- , and push it

slowly anti-clockwise.
– Maintain a torque of 40 Nm on torque wrench - VAS 6583- .
– Read value on the scale.
– If the chain skips during the test, renew timing chain
⇒ “1.5 Removing and installing timing chain and chain drive
for oil pump”, page 114 .
– If the chain skips, it can be heard and felt clearly.
Evaluation of the test
– If a chain elongation of up to 28° has been determined during
the test, the timing chain is OK.
– If a chain elongation of 29° or more has been determined, the
timing chain is not OK and must be renewed
⇒ “1.5 Removing and installing timing chain and chain drive
for oil pump”, page 114 .
Assemble in reverse order of dismantling. During this procedure,
observe the following:
Note
♦ The scale sleeve - T10550/3- is equipped with magnets.

♦ Do not use any levers for removing the scale sleeve -
T10550/3- from the belt pulley!
– Turn scale sleeve - T10550/3- towards right by approx. 45° so

that indicator - T10550/2- is not positioned within range of
scale.
– Grasp behind scale sleeve - T10550/3- with both hands.
– Press thumbs against bolt of belt pulley, and pull off scale
sleeve - T10550/3- .
– Renew oil seals for camshaft sealing cover and oil them before
fitting.
– Add coolant ⇒ “1.4 Draining and adding coolant”, page 159 .
Torque settings
♦ ⇒ “2.1 Assembly overview”, page 134
♦ ⇒ “1.4 Removing and installing poly-V belt”, page 51
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly over‐
view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres

– Place engine cover panel on camshaft housing and engage

coolant hoses -2- in bracket.
1.5 Removing and installing timing chain and chain drive for oil pump

equipment required

A-


♦ Pin - T40011-
♦ Locking pin - T10340- (not illustrated)

♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Removing
– Drain coolant

– Pull connector -1- off turbocharger air recirculation valve -

N249- .
– Detach hoses -2- at pressure pipe and open wiring guide -3-.

low.
Note
Disregard item -1-.

from cylinder head.
– Remove spark plug from No. 1 cylinder. To do this, use puller
- T10094 A- and spark plug socket and extension - 3122 B-
page 363 .
– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to

The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.
Note
♦ If crankshaft is turned 0.01 mm past TDC, turn crankshaft two

full turns in direction of engine rotation to set crankshaft in di‐
rection of engine rotation at TDC for No. 1 cylinder.
♦ Permissible deviation from TDC for No. 1 cylinder: ± 0.01 mm.
Caution

be renewed.
– Insert camshaft clamp - T10171 B- to stop in camshaft open‐

ings.
– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 B- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 B- .

– Pull cover -1- off sprocket for oil pump.

– Press tensioning rail in -direction of arrow- by hand and lock

piston of chain tensioner with locking pin - T40011- .
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Caution
Camshaft adjuster securing bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .
– Hold oil pump sprocket with counterhold - T10172- and loosen

securing bolt -1-.
– Use a screwdriver on bolt -2- to release tensioning spring -1-

then remove tensioning spring -1-.
– Unscrew securing bolt -3- and remove chain tensioner.
– Mark direction of rotation of oil pump drive chain -2- using felt-
tip marker.

– Unscrew securing bolt for sprocket -1- and remove sprockets

-1- and -3- together with drive chain for oil pump -2-.
Installing
• The crankshaft must be positioned at TDC for No. 1 cylinder.
– Push sprocket -1- in -direction of arrow- onto crankshaft jour‐

nal as far as the stop.
Caution
Cast lug -2- on sprocket -1- must seat in groove -3- on crank‐
shaft journal.
– Mark position of sprocket and crankshaft to cylinder block us‐

ing a felt-tip marker.
– Place oil pump drive chain -3- onto sprocket -1- while posi‐
tioning sprocket -2- on oil pump drive shaft.
Note
♦ Note running direction mark on oil pump drive chain.

♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
position -arrow-.

– Hold oil pump drive sprocket with counterhold - T10172- .

– Tighten new securing bolt -1- to 20 Nm + 1/4 turn (90°) further.
– Position chain tensioner on oil pump drive chain and tighten

securing bolt -3- to 8 Nm.
– Lever tensioning spring -1- onto bolt -2- using a screwdriver.
Note
♦ Note marks -arrows-.

♦ The crankshaft must remain stationary.
– Tighten sprocket -3- hand-tight with new securing bolt.
– Place timing chain -1- on crankshaft sprocket -4-, exhaust

camshaft sprocket -3-, and tighten camshaft adjuster -2- hand-
tight using a new securing bolt.
Note
♦ Note running direction mark on timing chain -1-.

♦ Ensure guide sleeve is installed between inlet camshaft and
camshaft adjuster.
♦ Camshaft adjuster securing bolt -2- has a left-hand thread.
Timing chain must lie on guide rail -1- and crankshaft sprocket
-arrow-.

– Install chain tensioner -1- and tighten securing bolts -2- to

9 Nm.
– Tension timing chain by pulling locking pin - T40011- from
chain tensioner.
– Check marks on crankshaft sprocket and cylinder block; they
must align.
– Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use

counterhold -T10172- ).
Note
♦ Securing bolts -2- and -4- are only tightened 90° further once
timing has been checked.
♦ The camshaft adjuster securing bolt -2- has a left-hand thread.
– Unscrew bolt -arrow- and remove camshaft clamp - T10171

B- from camshaft housing.
– Check valve timing ⇒ “1.2 Checking valve timing”, page 97
If valve timing is OK:
– Hold camshaft wheels with counterhold -T10172- and tighten

bolts -2- (left-hand thread) and -4- a 1/4 turn (90°) further with
a rigid wrench.
Note
Camshaft adjuster securing bolt -2- has a left-hand thread.
Note
Camshaft sprockets cannot move on camshaft whilst tightening.

– Install oil pump wheel cover -1-.

– Install valve timing housing
– Install crankshaft pulley
– Install poly V-belt
– Fill coolant system with coolant
quence.

1.6 Removing and installing camshaft housing


equipment required

A-
♦ Pin - T40011-


♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
♦ Two studs (M6x80)
♦ D 154 103 A1 Sealant
1.6.1 Removing
Note
♦ The camshafts are mounted in the camshaft housing on this

engine. Before removing camshaft housing, first remove valve
timing housing
♦ The camshaft housing sealing surface cannot be reworked.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– Disconnect battery earth strap with ignition switched off.
– Drain coolant

N249- .
– Unscrew bolts of both camshaft covers -3-.


from cylinder head.
– Remove turbocharger
⇒ “1.4 Removing and installing turbocharger”, page 277 .
– Turn crankshaft to TDC for No. 1 cylinder. Then turn crank‐
shaft 45° in engine direction and remove camshaft timing
sprockets with timing chain
– Unbolt camshaft sealing covers.
– Pull connectors off fuel pressure sender for low-pressure -
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.
– Remove ignition coils. Use puller -T10094 A- for this purpose
page 363 .
– Remove cable guide with wiring harness from camshaft hous‐
ing.
WARNING
– Pull connector and fuel supply line -arrows- off high-pressure

pump.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.

Note
Disregard item -1-.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
– Loosen union nuts -3- and -1- of high-pressure line.

– Disconnect connector off Hall sender - G40- .
– Remove lower part of intake manifold ⇒ Item 17 (page 303) .
– Unbolt left lifting eye.
– Loosen camshaft housing bolts from outside to inside, alter‐
nately and diagonally and remove.
– Carefully lift camshaft housing off.
1.6.2 Installing
Caution
The studs (M6x80) must be screwed into cylinder head before

installing camshaft housing.
The camshaft housing is guided by the studs, so that the roller
rocker fingers do not slip off the supporting elements.
Condition
• The pistons cannot be positioned at TDC.
– Remove sealant residues from cylinder head and camshaft
housing with a rotating brush, e.g. a hand drill with a plastic
brush (wear eye protection).
– Clean sealing surfaces carefully. They must be free of oil and
grease.
– Also prevent dirt and residual sealant from entering cylinder
head.
Caution

be renewed.

– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 B- can be pushed into holes in camshaft to stop.
– Secure camshaft clamp -T10171 B- hand-tight with an M6 bolt
(do not tighten).
Sealing on cylinder head with no sealing ring in area of spark plug
recess
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See yellow area in illustration.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Sealing on cylinder head with sealing ring in area of spark plug

recess
– Place 4 new sealing rings into grooves in cylinder head.
– Apply thin, even coat of sealant on clean camshaft housing

sealing surface. See yellow area in illustration.
– Do not apply sealant in area of -arrows-.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
– Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective
support elements -2-.
– Screw two studs (M6x80) into cylinder head before installing
camshaft housing.

– Carefully fit camshaft housing vertically onto studs -arrows-

and dowel pins of cylinder head from above.
Note
Ensure that no oil residue can drip onto sealing surfaces.
– Evenly tighten new camshaft housing securing bolts from in‐

side to outside alternately and diagonally.
Ensure that camshaft housing is not canted. Specified torque:
10 Nm + 1/4 turn (90°) further.
Note
After installing the camshaft housing, wait about 30 minutes for

the sealant to dry.
– Adjust valve timing ⇒ “1.3 Adjusting valve timing”, page 99 .

♦ Install valve timing housing
♦ Install turbocharger
⇒ “1.4 Removing and installing turbocharger”, page 277 .
♦ Install crankshaft pulley
♦ Attach fuel lines
⇒ “1.10 Assembly overview - high-pressure pump”,
page 311 .

1.7 Removing and installing cylinder head


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8- (Golf, Golf Plus)
♦ Adapter - 10 - 222 A /22- (Touran, Tiguan)
♦ Bracket - T10358-
Removing
Remove following components:
♦ Removing and installing valve timing housing ⇒ page 46 .
♦ Remove thermostat housing from cylinder head.
♦ Remove camshaft adjuster ⇒ page 99 .
♦ Remove tensioning and guide rail for timing chain.
♦ Removing and installing turbocharger ⇒ page 277 .
♦ Removing and installing intake manifold ⇒ page 310 .

Scirocco
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /8-
as shown.
– Position adapter - 10 - 222 A /8- on vehicle front end
-arrows- as shown.
All vehicles
– Unscrew securing bolt for gearbox and attach bracket -

T10358- as shown.
– Attach hooks of support bracket - 10 - 222 A- to bracket -
T10358- as shown.
– Turn spindle until the hooks are lightly tensioned.
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.

– Loosen cylinder head bolts in sequence given and then re‐

move completely.
– Carefully remove cylinder head.
Installing
Condition
• The pistons cannot be positioned at TDC.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft approx. 45° in engine direction of rotation.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.
– Tighten cylinder head in sequence as follows:

Specified torque/turning further angle
Stage Torque setting
1 30 Nm
2 Turn 90° further using rigid
wrench
wrench
wrench
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Install camshaft housing.
– Adjust valve timing ⇒ page 99 .
quence.
1.8 Checking compression


equipment required

♦ Compression tester - V.A.G 1763-
Prerequisites for check
• The engine oil temperature must be at least 30 °C.

Procedure
– Remove ignition coils. Use puller -T10094 A- for this purpose.
– Unscrew spark plugs with spark plug socket and extension -
3122 B- ⇒ page 363 .
– 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.
– Check compression using compression tester - V.A.G 1763- ,

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
Note
Using compression tester: ⇒ Operating instructions .
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New bar pressure Wear limit bar pres‐ Difference between
sure cylinders bar pres‐
sure
10.0 … 15.0 7.0 max. 3.0
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 30 Nm.
quence.
– Read event memory, rectify any faults and then clear event
memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
The readiness code must be generated if the event memory has
been cleared.

2 Repairing valve gear

Checking camshaft axial clearance ⇒ page 136 .
Removing and installing camshaft ⇒ page 136 .
Reworking valve seats ⇒ page 137 .
Checking valve guides ⇒ page 138
Renewing valve stem seals ⇒ page 139
1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ Left-hand thread
❑ Renew
2 - Camshaft adjuster
❑ Must not be dismantled.
⇒ page 99
3 - Camshaft sprocket
❑ Note position when in‐
stalling timing chain.
4 - O-ring
❑ Renew if damaged
❑ Before installing, coat
lightly with engine oil.
5 - Inlet camshaft control valve
1 - N205-
6 - 10 Nm
7 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
8 - Camshaft case
Caution
The studs (M6x80) must
be screwed into cylinder
head before installing
camshaft housing.
The camshaft housing is
guided by the studs, so
that the roller rocker fin‐
gers do not slip off the
supporting elements.

❑ Remove sealant residue.
❑ Coat with D 154 103 A1 before fitting

❑ When installing, fit vertically from above onto studs and dowel pins.
9 - 10 Nm
10 - Cap
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker fingers
❑ Check roller bearing.
❑ When installing, secure to supporting element using securing clip.
12 - Valve cotters
13 - Valve stem seal
❑ Renew
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Before installing, check camshaft axial clearance ⇒ page 136 .
15 - Valve guide
16 - Valve springs
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ page 139 .
17 - Cylinder head
❑ Reworking valve seats ⇒ page 137 .
❑ Reworking sealing surface ⇒ page 136 .
18 - Valves
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ page 136
19 - Exhaust camshaft
❑ Do not interchange with inlet camshaft.
❑ Checking axial clearance ⇒ page 136 .
❑ Coat with oil before inserting (also axial bearing shoulder).
20 - Guide bush
21 - Inlet camshaft
❑ With cam for high-pressure pump -arrow-.
❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
❑ Checking axial clearance ⇒ page 136 .
❑ Coat with oil before inserting (also axial bearing shoulder).
22 - 50 Nm + 1/4 turn (90°) further
❑ Renew after each removal
2. Repairing valve gear 135

Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 108.25 mm
Note
When the sealing surface has been reworked, the valves must be
set deeper by the same amount (valve seat inserts reworked) or
valves will contact pistons. When doing this, ensure that the per‐
missible minimum dimension is maintained ⇒ page 137 .
2.2 Checking camshaft axial clearance

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Perform measurements with camshaft housing removed and cap
fitted.
Checking camshaft axial clearance
Wear limit: max. 0.40 mm
Valve dimensions
Note
Do not rework valves. Only lapping-in is permitted.
Dimension Inlet valve Outlet valve

∅a mm 29.5 26.0
∅b mm 5.973 5.953
c mm 100.9 100.5
α ∠° 45 45
2.3 Removing and installing camshaft

Removing
– Remove high-pressure pump ⇒ page 315 .
– Remove camshaft housing ⇒ page 122 .
– Place camshaft housing down on a clean surface so that cam‐
shafts face upwards.

Note
♦ Camshafts may not be interchanged.

♦ Mark inlet camshaft and exhaust camshaft with a pen.
– Carefully pull out camshafts from camshaft housing.

Installing
– Before installing camshaft bearings, coat lightly with clean en‐
gine oil.
– Carefully push camshafts into camshaft housing as far as they
will go.
If installing new camshafts:
Observe allocation of exhaust camshaft and inlet camshaft ac‐
cording to part number ⇒ Electronic Parts Catalogue (ETKA) .
Inlet camshaft can also be identified by cam for high-pressure
pump.
Installation is performed in the reverse order of removal.
– Install camshaft housing ⇒ page 122 .
– Installing high-pressure pump ⇒ page 315 .
2.4 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 138 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

lows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.

– Measure distance between end of valve stem and upper edge

of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
-Measured distance 8.0 mm
Minimum dimension 7.6 mm
=max. perm. rework dimension3) 0.4 mm
3) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.
Reworking inlet valve seat

a = 28.7 mm diameter
b = max. permissible reworking dimension1
c = 1.5 … 1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
4) Calculating max. permissible reworking dimension ⇒ page 137 .
Reworking exhaust valve seat
a 25.0 mm ∅
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
5) Calculating max. permissible reworking dimension ⇒ page 137 .
2.5 Checking valve guides

♦ Dial gauge

Test sequence
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock by moving valve in direction of -arrow-.
Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
2.6 Renewing valve stem seals

equipment required
♦ Spark plug socket - 3122B-

♦ Valve spring tool - 3362- with thrust piece - 3362/1-
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-

♦ Pressure hose - VW 653/3-

Removing
(With cylinder head installed)
– Remove camshaft housing ⇒ page 122 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .
– Now screw pressure hose -VW 653/3- into spark plug hole.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals with 3364.
Installing
– Place plastic sleeve supplied on respective valve stem. This

will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft housing ⇒ page 122 .
– Adjust valve timing ⇒ page 99 .
♦ Installing valve timing housing ⇒ page 46 .
♦ Install fuel lines ⇒ page 315

17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renewing oil filter.
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 144 .
Engine oil, oil capacities, engine oil specification ⇒ page 141

Assembly overview (► model year 2008) ⇒ page 141
Assembly overview (model year 2009 ►) ⇒ page 144
Removing and installing sump ⇒ page 146 .
Removing and installing oil pump ⇒ page 149 .
Checking oil pressure and oil pressure switch ⇒ page 151
1.1 Engine oil, oil capacities, engine oil

specification
Oil capacities (Golf, Golf Plus, Passat, Passat Estate, Scirocco,
Eos)
With oil filter, 3.6 l
Oil capacities (Tiguan)
With oil filter, 4.0 l
Engine oil specifications
⇒ Maintenance ; Booklet ; Service tables
Changing engine oil: “Engine oil: Drain or extract”
⇒ Maintenance ; Booklet ; Service tables .
1.2 Assembly overview (► model year 2008)
1. Removing and installing parts of lubrication system 141

1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 144 .
2 - Engine oil cooler
3 - O-ring
❑ Renew
4 - Coolant pipe
❑ For engine oil cooler
❑ Specified torque, brack‐
et to crankcase: 20 Nm.
5 - 8 Nm
❑ Engine oil cooler torque
setting: 8 Nm + 90°.
❑ Renew engine oil cooler
bolts.
6 - Cap
❑ Renew seal if damaged.
7 - Seal
8 - Oil filter cover, 25 Nm
Note
Cover alternator with cloth before

removing.
❑ With bypass valve,
opening pressure: 2.50
bar
❑ With non-return valve
9 - Filter element
10 - Valve
❑ Install with sealant D 176 501 A1.
❑ Removing and installing valve timing housing ⇒ page 46
❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide.
❑ To guide valve timing housing, secure sump in position with two bolts.
12 - 10 Nm
13 - 150 Nm + 1/2 turn (180°) further
❑ Renew
❑ Secure pulley against turning with counterhold 3415.
14 - Pulley
❑ Contact surfaces of pulley must be free of oil and grease.
❑ Secure pulley against turning with counterhold -3415- .
142 Rep. gr.17 - Lubrication

15 - Seal
❑ Renew
16 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
17 - Seal
18 - Sprocket
19 - 20 Nm + 1/4 turn (90°) further
❑ Renew
20 - Sprocket
❑ For oil pump.
❑ Lock with counterhold -T10172- .
21 - Drive chain
❑ For oil pump.
22 - 10 Nm
23 - Oil level and oil temperature sender - G266-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
24 - Oil drain plug, 30 Nm
❑ With captive seal
❑ Renew
25 - 13 Nm
❑ Renew
❑ Loosen and tighten flywheel end bolts only with Allen key, long reach 5 mm -T10058- .
26 - 45 Nm
27 - Sump
❑ Install with silicone sealant D 176 600 A1
28 - 14 Nm + 1/4 turn (90°) further
29 - Oil pump
❑ Renew only as complete unit
30 - 5 Nm
31 - Oil separator

Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched zone: engine oil can be added
c - Area from min. mark up to hatched field: top up with max. 0.5 l
of engine oil!
1.3 Assembly overview (model year 2009 ►)
1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 146 .
3 - O-ring
❑ Renew
4 - Coolant pipe
❑ For engine oil cooler
❑ Specified torque, brack‐
et to crankcase: 20 Nm.
5 - 8 Nm
❑ Engine oil cooler torque
setting: 8 Nm + 90°.
❑ Renew engine oil cooler
bolts.
6 - Cap
❑ Renew seal if damaged.
7 - Seal
8 - Oil filter, 20 Nm
❑ Loosen with oil filter tool
- 3417- .
❑ Observe fitting instruc‐
tions on oil filter
❑ With non-return valve
❑ Additionally install with
silicone adhesive seal‐
ant - D 176 501 A1- .
❑ Removing and installing valve timing housing ⇒ page 46
❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide.
❑ To guide valve timing housing, secure sump in position with two bolts.
10 - 10 Nm
11 - 150 Nm + 1/2 turn (180°) further
❑ Renew

12 - Pulley
❑ Contact surfaces of pulley must be free of oil and grease.
13 - Seal
❑ Renew
14 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
15 - Seal
16 - Sprocket
17 - 20 Nm + 1/4 turn (90°) further
❑ Renew
18 - Sprocket
❑ For oil pump.
❑ Lock with counterhold - T10172- .
19 - Drive chain
❑ For oil pump.
20 - 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
22 - Oil drain plug, 30 Nm
❑ With captive seal
❑ Renew
23 - 13 Nm
❑ Renew
❑ Loosen and tighten flywheel end bolts only with long-reach Allen key - T10058- .
24 - 40 Nm
25 - Sump
❑ Install with silicone sealant - D 176 600 A1- .
26 - 14 Nm + 1/4 turn (90°) further
27 - Oil pump
❑ Renew only as complete unit

28 - 5 Nm
29 - Oil separator
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched zone: engine oil can be added
c - Area from min. mark up to hatched field: top up with max. 0.5 l
of engine oil!
1.4 Removing and installing oil sump

♦ Wedge - T10383/2-

♦ Cutting tool - T10561-
♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
♦ Silicone sealant D 176 600 A1
Removing
Rep. gr. 50 ; Removing and installing noise insulation .
– Drain engine oil ⇒ Maintenance ; Booklet 36.1 .
– Disconnect front exhaust pipe from catalytic converter
⇒ “1.1 Assembly overview - catalytic converter and attach‐
ments”, page 348 .
– Remove front right wheel housing liners ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - front wheel housing liner .
– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Remove bolts from sump.
Note
♦ The sump is sealed with liquid sealant ⇒ Electronic Parts

Catalogue .
♦ When hardened, the sealant has a high adhesive strength.
♦ Two bolts must be loosened but not removed to secure the
sump from falling after seal has been cut.
– Cut through seal between oil sump -4- and engine -1-.
– Use cutting tool - T10561- to do this.
• Centre the cut between bolts -3- only.
– 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.
Note
When the seal has been broken, a sucking noise will be heard as
the sump detaches.
– 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.
– Release sump carefully from adhesive.
– Remove bolts which are still holding sump.
– Remove sump.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.

an electric drill with plastic brush attachment (wear eye pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Check the expiry date of the sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.

– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

nozzle).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be:
♦ 2 to 3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead cannot be thicker, or excessive seal‐

ing compound will enter the sump and may block the oil suction
pipe strainer.
– Install sump immediately and tighten all sump bolts lightly.

– Tighten oil sump bolts to specified torque ⇒ page 149 .
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
Specified torques:
Component Torque set‐ Note
ting
Securing bolt 13 Nm Loosen and tighten fly‐
sump/crankcase wheel-end bolts with Allen
key, long reach 5 mm -
T10058-
Bolt for securing 40 Nm
sump to gearbox
Oil drain plug 30 Nm Renew (with captive seal)
♦ Securing bolts, front exhaust pipe/catalytic converter
⇒ “1.1 Assembly overview - catalytic converter and attach‐
ments”, page 348
1.5 Removing and installing oil pump

Removing

– Pull cover -1- off sprocket for oil pump.

– Hold oil pump sprocket with counterhold - T10172- .
– Loosen sprocket securing bolt.
Note
Do not remove bolt completely.
– Press chain tensioner in direction of arrow with a screwdriver.

– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.
– Loosen oil pump securing bolts -arrows- and remove them.

– Remove oil pump from cylinder block.
Installing

– Press chain tensioner in direction of arrow with a screwdriver.

– Insert sprocket in chain and fit sprocket onto oil pump shaft.
– Observe installation position of sprocket on oil pump shaft

-arrows-.
– Screw in sprocket securing bolt.
– Hold sprocket with counterhold - T10172- .
– Fit torque wrench (5…50 Nm) - V.A.G. 1331- as shown.

– Tighten securing bolt to 20 Nm +1/4 turn (90°) further.
1.6 Checking oil pressure and oil pressure switch


equipment required
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Adapter set - V.A.G 1594C-
♦ 10 mm jointed spanner - T40175-
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
The oil pressure switch is located on the gearbox side beneath
the two camshaft covers.

– Remove bolt -1- on coolant pipe bracket.

– Pull connector off oil pressure switch -arrow-.
– Remove oil pressure switch - F1- using 24 mm jointed spanner

- T40175- and screw it into oil pressure tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- .
– If LED lights up, renew oil pressure switch -F1- .
If LED does not light up:
– Start engine and increase speed slowly. At 0.3…0.7 bar, the
LED must light up, otherwise the oil pressure switch must be
renewed.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80°C; the oil pressure should be at least 2.0 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If oil pressure switch is OK, remove old seal and renew ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
Specified torque for oil pressure switch: 20 Nm

19 – Cooling
1 Removing and installing parts of cool‐
ing system
Caution
♦ Observe the following points during all installation work, in

particular in the engine compartment, due to the space
limitations:
sitions.
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- or spring-type clip pliers - VAS
5024A- are recommended for use in installing spring-type
clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Test for leaks in cooling system using cooling system tester -

V.A.G 1274 B- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Assembly overview - parts of cooling system, body side
⇒ page 155 .
Assembly overview - parts of cooling system, engine side
⇒ page 157 .
Connection diagram for coolant hoses ⇒ page 158
Draining and filling with coolant ⇒ page 159 .
Checking cooling system for leaks ⇒ page 164 .
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- ⇒ page 162 .
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- (Tiguan) ⇒ page 163
Removing and installing radiator ⇒ page 165
Removing and installing radiator (Tiguan, Passat) ⇒ page 167
Removing and installing auxiliary radiator (Tiguan, Passat)
⇒ page 169
Removing and installing coolant pump ⇒ page 173 .
Removing and installing coolant circulation pump - V50-
⇒ page 175 .
154 Rep. gr.19 - Cooling

1.1 Assembly overview - parts of cooling system, body side
Note
This engine is equipped with an auxiliary radiator for charge air system ⇒ page 297 .
1 - Radiator/cooler
⇒ page 165
in the Tiguan and Pas‐
sat ⇒ page 167 .
❑ After renewing, renew
entire coolant.
2 - O-ring
3 - Upper coolant hose
❑ To connection on cylin‐
der head.
❑ Connection diagram for
coolant hoses
⇒ page 158
4 - Coolant hose
❑ To expansion tank
5 - Spring-type clip
❑ Remove and install with
hose clip pliers - VAS
6340-
6 - Coolant hose
❑ To coolant pipe for aux‐
iliary radiator for charge
air system.
7 - Connecting pipe
8 - 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-
9 - Connector
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
❑ 5 Nm
❑ Qty. 2
12 - Plastic inserts
❑ For securing bolts.
1. Removing and installing parts of cooling system 155

13 - Bracket
14 - Cowling
❑ Removing and installing in the Tiguan and Passat ⇒ page 163 .
15 - Bolt
❑ 5 Nm
❑ Qty. 4
16 - Radiator fan 2 - V177-
17 - Connector
18 - Radiator fan - V7-
❑ With radiator fan control unit - J293-
19 - Bracket
❑ For connector.
20 - Lower coolant hose
❑ To connection for thermostat.
21 - Retaining clip
22 - Radiator outlet coolant temperature sender - G83-
23 - Bolt
❑ 5 Nm
❑ Qty. 6

1.2 Assembly overview - parts of cooling system, engine side

Thermostat side
1 - Union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Push rod
❑ Do not cant when instal‐
ling
5 - Thermostat
Note
Do not interchange thermal ele‐

ments.
Starts to open
❑ Thermal element (bot‐
tom of illustration): 83°C
❑ Thermal element (top of
illustration): 105°C.
6 - Radiator outlet coolant -
G62-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
7 - Retaining clip
❑ Check for firm seating
8 - Thermostat housing
9 - Seal
❑ Renew
10 - 11 Nm
11 - To expansion tank
❑ Connection diagram for coolant hoses ⇒ page 158
12 - Union
13 - Coolant pipe
14 - Coolant pipe
15 - 5 Nm
16 - From bottom of radiator.
17 - To top of radiator

1.3 Coolant hose connection diagram
1 - Expansion tank
2 - Coolant circulation pump -
V50-
⇒ page 175
3 - Intake manifold
4 - Non-return valve
5 - Heat exchanger for heater
6 - Thermostat housing
7 - Restrictor
9 - Radiator/cooler
10 - Auxiliary radiator for
charge air system
❑ Removing and instal‐
ling, Golf, Golf Plus,
Scirocco, Eos
⇒ page 165
❑ Removing and instal‐
ling, Tiguan and Passat
⇒ page 169
⇒ page 277
12 - Cylinder head/cylinder
block
❑ If renewed, refill system
with fresh coolant.
13 - Coolant pump
⇒ page 173
14 - Auxiliary heater
❑ Optional equipment

1.4 Draining and adding coolant

equipment required
♦ Refractometer - T10007 A-
♦ Coolant system charge unit - VAS 6096-
Draining
WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Open filler cap on coolant expansion tank.

or skid plate .

Drain coolant from engine cooling system

– Pull off retaining clip -arrow- and remove coolant hose from
radiator.
Note
Please observe disposal instructions!
Draining coolant from charge air cooling system

– Disconnect coolant hose (quick-release coupling) -arrow- from
lower connection of auxiliary radiator for charge air system.
Note
Please observe disposal instructions!
Filling
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

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, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ 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.
Recommended mixing ratios (use only distilled water for mixing):

Frost Amount of anti- Coolant ad‐ Distilled wa‐
protection to freeze ditive 6) ter 6)
-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
6) The quantity of coolant can vary depending upon vehicle equipment.

– Press connection against radiator and slide retaining clip

-arrow- into groove.
or skid plate .
With cooling system charge unit - VAS 6096-
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
Without cooling system charge unit - VAS 6096-
– Switch off heating and air conditioning system.
– Fill with coolant up to max. mark on expansion tank.

– Connect ⇒ Vehicle diagnostic tester and perform guided func‐
tion “Filling and bleeding cooling system”.
WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Check coolant level and top up as needed. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark and between the min. and max. marks when
the engine is cold.
1.5 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (Golf, Golf
Plus, Eos, Scirocco)
Removing radiator fan
– Remove engine cover.
– Remove upper securing bolts of cowling -arrows-.
Rep. gr. 50 ; Body - front; Noise insulation .

– Separate connector -1- and unscrew lower cowling securing

bolts -arrows-.
– Separate electrical connector -1- and free wiring.

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
note the following:
Torque setting
Component Nm
Radiator fan to cowling 10
Cowling to radiator 5
1.6 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (Tiguan,
Passat)
Removing radiator fan
or skid plate .
– Remove engine cover panel.

– Uncover cables -1-.

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
the following:
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Torque setting
Component Nm
Radiator fan to cowling 10
1.7 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-

• Engine at operating temperature.

Test sequence
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on tester to create a pressure of about 1.0 bar.
WARNING
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.
If the pressure drops:

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:
– Renew sealing cap.
– Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew sealing cap.
1.8 Removing and installing radiator (Golf, Golf Plus, Scirocco, Eos)


equipment required
Removing
– Pull coolant hoses off radiator.
– Pull connectors off thermal switch and radiator fan.
– Remove radiator securing bolts -arrows-.
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Assembly overview .

– Undo and remove coolant pump bolts -arrows- of the radiator

support.
Removing auxiliary radiator
sition .
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.

– Unbolt condenser from radiator and secure to lock carrier.
Installing
note the following:
Filling with new coolant ⇒ page 159 .
Torque setting
Component Nm
Radiator to auxiliary radiator 5
1.9 Removing and installing radiator (Tiguan, Passat)


equipment required
Removing
or skid plate .
– Pull coolant hoses -1- and -2- off radiator.

Tiguan
-arrows-.

– Remove radiator securing bolts -arrows- and take out radiator

downwards.
Installing
the following:
Fill with coolant ⇒ page 159 .
Specified torques:
Component Nm
Radiator to auxiliary radiator for charge air system 5
1.10 Removing and installing auxiliary radiator for charge air system (Tiguan,
Passat)


equipment required
Note
The auxiliary radiator cools the charge air cooler ⇒ page 297 .
Removing
or skid plate .

Tiguan
– Bring lock carrier into service position: ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Front body: Lock carrier - service
position .
-arrows-.
Passat up to 10.2010
– Bring lock carrier into service position: ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Front body: Lock carrier - service
position .
Passat from 11.2010
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper .
– Pull coolant hoses -1- and -2- off radiator.


– Drain coolant from chair air system by detaching the coolant

hose -arrow- from the lower connection of the auxiliary radiator
for coolant.
– Pull off coolant hose -1- after first releasing the retaining clip.
– Remove radiator securing bolts -arrows- and take out radiator

downwards.
– Undo and remove coolant pump bolts -arrows- of the radiator

support.


– Remove securing bolt -arrow-.
– Pull auxiliary radiator for charge air system out of its support
from below.
– Swivel auxiliary radiator for charge air system towards the
rear.
– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier.
Note


– Pull auxiliary radiator for charge air system out of its support
from below.
– Take out auxiliary radiator for charge air system downwards.
Installing
the following:
Fill with new coolant ⇒ page 159 .
Torque setting
Component Nm
Radiator to auxiliary radiator for charge air system 5
Auxiliary radiator for charge air system to lock carrier 5
Coolant lines to auxiliary radiator for charge air system 5
Condenser to auxiliary radiator for charge air system 5
1.11 Removing and installing coolant pump


equipment required
♦ Water pump wrench - V.A.G 1590-
– Due to modification to securing bolts for coolant pump pulley,
the 3 rounded corners must be filed out to minimum a = 1 mm.
Modifying water pump wrench V.A.G 1590
Note
♦ Do not separate the integrated coolant pump seal from the

coolant pump.
♦ Damaged or leaking coolant pumps must be renewed com‐
plete with seal.
Removing

– Remove bracket -1-.
Note
As the bracket is only used during the vehicle production, it need

not be reinstalled.
– Hold pulley with water pump wrench - V.A.G 1590- .

– Unscrew securing bolts -arrows- for coolant pump pulley and
remove pulley.
– Unscrew securing bolts -arrows- for coolant pump -1- and pull
pump off cylinder block.
Installing
note the following:
– Install coolant pump in cylinder block.
– Tighten securing bolts to 9 Nm.
– Tighten coolant pump pulley to 20 Nm.
1.12 Removing and installing coolant circulation pump - V50-


equipment required
♦ Hose clamps to 40 mm - 3093-

Removing
WARNING
The cooling system is under pressure when the engine is hot!

Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
The fitting location of the coolant circulation pump - V50- is be‐

neath the intake manifold.
or skid plate .
– Seal off water hoses with hose clamps up to 40 mm - 3093- .
– Open clips and pull coolant hoses -2- off.
Installing
note the following:
– Check coolant level and top up if necessary ⇒ page 159 .
Torque setting
Component Torque setting
Securing bolt 10 Nm

20 – Fuel supply system

1 Safety precautions
Safety precautions when working on fuel supply system
⇒ page 178 .
Releasing pressure in high-pressure area ⇒ page 179 .
1.1 Safety regulations for working on fuel

supply
Caution

sitions.
When removing and installing fuel gauge sender - G- or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
Remove fuel pump fuse. Fuse assignment ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations
WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
♦ Even before work starts, the extraction hose of a fume extrac‐

tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
178 Rep. gr.20 - Fuel supply system

1.2 Releasing pressure in high-pressure

area
WARNING
The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx.
6 bar).
Prior to opening the high-pressure area, e.g. when removing
the high-pressure pump, fuel rail, injectors, a fuel line, or the
fuel pressure sender - G247- , the fuel pressure in the high-
pressure area must be reduced to a residual pressure of
approx. 6 bar. The appropriate procedure is described as fol‐
lows.
– Connect ⇒ Vehicle diagnostic tester and perform guided func‐

tion “Releasing fuel high-pressure”.
– Switch off ignition.
WARNING
The fuel lines are pressurized! Wear protective goggles and

protective clothing to avoid injury and contact with the skin.
Before opening the high-pressure section, wrap a cloth around
the connection.
– Now wrap a clean cloth around the connection and carefully

open the connection to release residual pressure of approx. 6
bar. Catch the escaping fuel.
– After completing work, read event memory of engine control
unit and clear all event entries that may have been created as
a result of pulling off the connector.
Note
If the event memory was cleared, the readiness code must be

generated ⇒ Vehicle diagnostic tester “Guided Functions”.
1. Safety precautions 179

2 Separating plug-in connectors

♦ -T10468-
Assignment of plug-in connectors
Note
The plug-in connectors for fuel, vacuum and breather lines are
colour coded. There is either a coloured dot on the plug-in con‐
nector or the release button is coloured.
Plug-in connector Colour code on plug-in connec‐

tor
Fuel supply black
Fuel return line blue
Breather white, beige
Vacuum green
WARNING
Fuel supply line is pressurised. Wear protective goggles and

Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
Version 1
Plug-in connector with release buttons -arrows- on right and left

Open
It is necessary to counterhold the separating point for fuel -1-.
– Insert -T10468- between heat shield and stop -arrow- of fuel
line -2- and counterhold.
Continuation for all separating points of the fuel system

– Push plug-in connector -1- in -direction of arrow A-.
– Press release buttons and pull plug-in connector -1- off fuel
line -2- in -direction of arrow B-.
Note colour assignment during installation ⇒ page 180 .
– Ensure plug-in connector is secured properly by pulling it.
Version 2
Plug-in connector with pull-release mechanism -arrow-
2. Separating plug-in connectors 181

Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
Version 3
Plug-in connector with front button -arrow-
Open
– Press release button -arrow- and pull off plug-in connectors.
– Ensure plug-in connectors are secure properly by pulling.
Version 4
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
Version 5
Open
– Press release buttons -arrows- and pull off plug-in connector.

3 Fuel tank (Golf, Golf Plus, Scirocco)

⇒ page 178 .
Observe rules for cleanliness ⇒ page 213 .
Assembly overview - fuel tank ⇒ page 183 .
Emptying fuel tank ⇒ page 184 .
Removing and installing fuel tank ⇒ page 187 .
3.1 Assembly overview - fuel tank
1 - Cap
2 - Securing bolt
3 - Earth connection
❑ Ensure firm seating
4 - 10 Nm
5 - Wiring guide
6 - Fuel
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383 A- .
⇒ page 187
7 - 25 Nm
❑ Renew
Note
To secure the securing straps for

the fuel tank, only bolts with loose
washers must be used. This will
stop the securing straps from being
twisted out of position when tighten‐
ing the bolts.
8 - Clamping washer
9 - Securing strap
❑ Observe installation po‐
sition
Note

ing the bolts.
10 - Heat shield
11 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
3. Fuel tank (Golf, Golf Plus, Scirocco) 183

12 - Supply line
❑ To fuel rail
13 - Breather line
❑ Clipped onto side of fuel tank.
14 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
15 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 217 .
❑ Note installation position on fuel tank ⇒ page 184
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 216
❑ Clean strainer if soiled
16 - Locking ring 110 Nm
❑ Remove and install using wrench - T10202- .
17 - Supply line
❑ black
18 - Return line
❑ blue
19 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
Installation position of fuel delivery unit

Marking -3- on sender points opposite to direction of travel.
Return line (blue or with blue mark) -1-
Black supply line -2-
3.2 Emptying fuel tank


♦ Fuel extractor - VAS 5190-
♦ Special wrench - T10202-

– Note safety precautions before beginning work ⇒ page 178 .
Emptying fuel tank if it is more than 3/4 full ⇒ page 185 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 186
3.2.1 Emptying fuel tank if it is more than 3/4

full
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At a distance of -a- = 1180 mm from the end of the hose, mark
extraction hose with insulating tape -arrow-.

– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
♦ If work must be performed on fuel pump or fuel tank sender,
proceed as follows:
3.2.2 Emptying fuel tank if it is less than 3/4 full

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
– Remove cover from fuel delivery unit.
WARNING

off connection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.

– Open locking ring using key - T10202- .

– Raise fuel delivery unit.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 214 .
3.3 Removing and installing fuel tank

Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With the ignition switched off, disconnect battery earth strap.
– Unscrew securing bolts and remove tank flap unit.
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Remove cover from fuel delivery unit.

– Pull connector as well as supply and return lines -1 and 2- off

flange.
– Remove rear right wheel.
– Remove rear right wheel housing liner ⇒ General body re‐
housing liner; Rear wheel housing liner .
– Unbolt filler pipe from body -arrows-.

– Disconnect all rear exhaust system retainers from body. Then
support lowered exhaust system on body with wire.
WARNING
– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
Press in securing ring to release the fuel lines.
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Lower fuel tank.
Installing
the following:
Note
To secure the securing straps for the fuel tank, only bolts with
loose washers must be used. This will stop the securing straps
from being twisted out of position when tightening the bolts.
♦ Specified torque for securing bolt for securing strap: 25 Nm.

♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.

4 Fuel tank (Passat)

⇒ page 178 .
Rules for cleanliness ⇒ page 269 .
1 - Fuel line
2 - Cap
3 - Securing bolt
4 - Tank flap unit
⇒ General body repairs,
exterior; Rep. gr. 55 ;
Tank flap unit; Remov‐
ing and installing fuel
tank flap unit .
5 - Breather line
❑ Clipped onto fuel tank
7 - Fuel
1383 A- .
⇒ page 193
8 - Securing straps
Note

ing the bolts.
9 - Heat shield
10 - Clamping washer
11 - Bolt
❑ 25 Nm
❑ Renew
4. Fuel tank (Passat) 189

Note

ing the bolts.
12 - Seal
❑ Renew
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 233
14 - Suction-jet pump
15 - Flange with fuel filter
❑ With 6 bar pressure relief valve
16 - Locking ring
❑ 110 Nm


– Note safety precautions ⇒ page 178 .


full
Caution

part of the body.

– Use insulating tape to mark the extraction hose -arrow- at a

distance of -a- = 990 mm from the end of the hose.
Note
♦ The shaft end -1- and adapter -2- are not used.
♦ There is a flap on the lower end of the fuel filler neck in the fuel
tank which must not be damaged by the extraction hose. You
must therefore push hose into filler neck only as far as mark‐
ing.
– Push extraction hose into fuel tank until marking on hose co‐
incides with filler neck.
– Drain fuel tank via filler neck as far as possible.
– Pull extraction hose out carefully.
Note

♦ Draining fuel tank completely ⇒ page 192

– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Release connector -1- and fuel line -2- and pull them off flange
-3-.
Note

– Open locking ring using wrench - T10202- .

– Raise flange.
– Insert suction hose of fuel extractor - VAS 5190- as far as
possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall flange .
Torque setting
Locking ring 110 Nm

Removing fuel tank ⇒ page 193

Installing fuel tank ⇒ page 195
4.3.1 Removing fuel tank
Note
♦ The rear axle must be lowered to remove the fuel tank.

♦ Open tank flap and, if necessary, take adapter for wheel lock
out of luggage compartment before disconnecting battery.

– Check whether a coded radio is fitted. If so, obtain anti-theft
code:
– Disconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
Drain fuel tank with fuel extractor - VAS 5190- ⇒ page 190 .

fuel delivery unit.

– Remove right rear wheel.
– Pull breather line and pressure retention valve -arrow- off ac‐
tivated charcoal filter.
Note
Grasp securing ring (grey) on pressure retention valve and pull

valve off upwards.
– Unscrew tank flap unit securing bolt and remove tank flap unit
⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
– Unbolt filler neck from body -arrows-.

– Unclip wire from filler neck -arrows-.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
Note
– Separate breather line (white) and fuel line (black) at union.

– Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ;
Assembly overview: Subframe (front-wheel drive); Lowering
rear axle .
Note
When lowering, ensure sufficient clearance to brake lines and

electrical wiring.
– Unscrew bolts of tensioning straps -arrows-.
Note
With the help of a 2nd mechanic, secure fuel tank to prevent it

falling.
– Remove tensioning straps.

– With the help of a 2nd mechanic, lower the fuel tank slowly.
– With the aid of a 2nd mechanic, guide the filler neck out be‐
tween rear axle and body.
4.3.2 Installing fuel tank

the following:
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body.

– Slowly raise fuel tank into installation position and secure it.
Note
Tighten securing bolts -arrows-.

– Attach rear axle to body again ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42 ; Removing and installing rear axle .
♦ Check fuel tank/body earth connection on filler neck.
Torque setting
Tensioning straps to body 25 Nm
♦ To secure the securing straps for the fuel tank, only
bolts with loose washers must be used. This will
stop the securing straps from being twisted out of
position when tightening the bolts.
Filler neck to body 8 Nm + 90°

Subframe/rear axle to body ⇒ Running gear, axles, steering; Rep. gr. 42 ; Re‐
♦ Use new bolts! moving and installing rear axle .
Fitting wheels ⇒ Running gear; Rep. gr. 44 ; Specified torque for

mounting wheels

5 Fuel tank (Eos)

⇒ page 178 .
Rules for cleanliness ⇒ page 213 .
1 - Securing bolt
2 - Cap
4 - 10 Nm
5 - Cable bracket
6 - 25 Nm
❑ Renew
Note

ing the bolts.
7 - Fuel
1383 A- .
⇒ page 201
8 - Clamping washer
9 - Exhaust system retainer
10 - Securing strap
sition
Note

ing the bolts.
5. Fuel tank (Eos) 197

11 - Heat shield
12 - Supply line
❑ To fuel rail
13 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
14 - Breather line
15 - Seal
❑ Renew
❑ Note installation position on fuel tank ⇒ page 198
❑ With fuel gauge sender - G- , Removing and installing ⇒ page 216
18 - Supply line
❑ black
19 - Return line
❑ blue
20 - Tank flap unit
Installation position of fuel delivery unit

Marking -3- on sender points opposite to direction of travel.
Return line blue or with blue marking -1-
Black supply line -2-




full
Caution

part of the body.
– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 820 mm from the end of the hose.

– Push extraction hose into fuel tank until marking -arrow- on

hose coincides with filler neck.
Note
A ball valve is located at the lower end of filler neck in fuel tank,
which must not be damaged by the extraction hose -1-. Therefore
push hose into filler neck only as far as marking -arrow-.
– Empty fuel tank as far as possible.

– Carefully pull out extraction hose.
Note

♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 200 .

fuel delivery unit.
WARNING

off connection.
– Pull connector -1- and fuel lines -2- and -3- off flange.
Note
♦ Press in securing ring to release the fuel lines.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.


– Lift sender flange.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange
⇒ page 214 .

Removing
If necessary, empty fuel tank using fuel extractor - VAS 5190- ,
⇒ page 199 .

fuel delivery unit.
Note
For vehicles with auxiliary heater the metering pump - V54- con‐
nector must be separated additionally.
– Pull 5-pin connector -arrow- off flange.

– Remove rear right wheel.
– Unbolt filler neck from body -1-.

– Unclip electrical cable from filler neck -2-.
– Remove supports -A- and -B-.

– Remove centre and rear silencers.
– Remove heat shields from middle and rear silencers.
WARNING

off connection.

– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note

♦ Vehicles with auxiliary heater, the fuel line of the metering
pump - V54- must also be separated.
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Lower fuel tank.
Installing
the following:
Note

♦ Do not interchange supply and return lines (return line blue or
with blue marking, supply line black).
♦ Check earth connection on fuel tank and body to filler neck.
♦ Install radius rods ⇒ Running gear, axles, steering; Rep. gr.
42 ; Removing and installing radius rods .
Specified torques:
Component Nm
Fuel tank to body - M6 bolts 10
Fuel tank to body - M8 bolts1) 25
1) Renew

6 Fuel tank (Tiguan)

⇒ page 178 .
Comply with rules for cleanliness ⇒ page 244
Assembly overview - fuel tank (Tiguan) ⇒ page 204 .
Draining fuel tank (Tiguan) ⇒ page 206 .
Removing and installing fuel tank (Tiguan) ⇒ page 208 .
6.1 Assembly overview - fuel tank (Tiguan)
1 - Cap
2 - Securing bolt
4 - Breather line
❑ To activated charcoal fil‐
ter
❑ Remove and install us‐
ing wrench - T10202- .
⇒ page 245
❑ Checking fuel pump
⇒ page 253 .
❑ Note installation posi‐
tion on fuel tank
⇒ page 206
❑ With fuel gauge sender
- G-
fuel gauge sender - G-
⇒ page 247
7 - Supply line
❑ black
❑ Clipped onto side of fuel
tank.
8 - Fuel gauge sender 2 - G169-
❑ With integrated fuel filter
❑ With suction-jet pump

9 - 3.5 Nm
10 - Bracket for fuel pump control unit - J538-
11 - Fuel pump control unit - J538-
12 - Seal
❑ Renew
13 - Fuel
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
14 - 25 Nm
❑ Renew
Note

washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
15 - Securing strap
❑ Observe installation position
Note

washers must be used. If different
bolts are used, the securing straps
might twist during tightening.
16 - 20 Nm + 1/4 turn (90°) further

❑ Renew
17 - Clamping washer
18 - Heat shield
19 - Breather line
20 - Breather line
21 - 8 Nm + 1/4 turn (90°) further
❑ Renew
22 - Tank flap unit
6. Fuel tank (Tiguan) 205

Installation position of flange for fuel delivery unit and fuel gauge
sender 2 - G169-
Fuel delivery unit -3-:
The lug -1- points in direction of travel.
Fuel gauge sender 2 - G169- -2-:
The lug -1- points in direction of travel.
Note
The arrows on the locking rings may be disregarded.
6.2 Draining fuel tank (Tiguan)



full
Caution

part of the body.
– Remove cone piece -2- from shaft -1- of fuel extractor -

VAS 5190- .
– Make a mark -arrow- on hose with insulating tape at distance
-a- = 1200 mm from end of extraction hose.
– Remove fuel filler cap from filler neck.

– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; take care not to damage it with the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank via filler neck as far as possible.

– Pull extraction hose out carefully.
Note

♦ In order to carry out work on fuel pump or fuel tank sender,
proceed as follows ⇒ page 208 :


– Remove cover of fuel delivery unit.
WARNING

off connection.
– Release connector and fuel lines and pull them off flange.
Note

– Lift fuel delivery unit .
If fuel tank needs only to be emptied, install fuel delivery unit again
⇒ page 245 .
– Remove suction-jet pump ⇒ page 248 .
– If fuel tank needs only to be emptied, install suction-jet pump
again ⇒ page 248 .
Torque settings
Components Torque settings
Locking ring 110 Nm
6.3 Removing and installing fuel tank (Ti‐

guan)

Removing
coding.
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).
– Release connector -arrow- at fuel pump control unit - J538-

and pull off with the assembly tool - T10118- .

– Pull connector -1- off left flange (in direction of travel).
– Loosen nuts -arrows- of clamping sleeve and push it forwards

onto exhaust pipe -1-.
– Undo and remove bolts -arrows- and pull exhaust pipe towards
the rear.
– Remove rear exhaust system with centre and rear silencers
⇒ page 348 .
WARNING
– Disconnect fuel line -1- (black) and breather line -2- (white) at
connecting point.
– If an auxiliary heater is fitted, disconnect fuel line -3- as well.
Note
– Unbolt right rear wheel.


– Disconnect breather lines -1- from activated charcoal filter and

fuel tank filler neck -3-.
– Unclip cable -2- from bracket.
– Remove tank flap and cap of fuel tank filler neck.
– Detach earth wire at fuel tank filler neck.
– Unbolt filler neck from body -arrows-.
– Unscrew securing bolt -1-.

– Unscrew securing strap and securing bolts -arrows-. When
doing this, support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
Installing
the following:
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body.
– Then place fuel tank on engine and gearbox jack - V.A.G 1383
A- .
– Slowly raise fuel tank into installation position and secure it.
Note
loose washers must be used. If different bolts are used, the se‐
curing straps might twist during tightening.
Tighten the new bolts of the tensioning straps -arrows- and new
bolt -1-.

– Tighten securing bolts -arrows- for fuel tank filler neck.

Further installation is carried out in reverse order of removal. Dur‐
ing this procedure, observe the following:
♦ Check fuel tank/body earth connection on filler neck.
♦ After installing fuel tank, check that supply and breather lines
are still clipped onto fuel tank.
Torque setting
Tensioning straps to body 25 Nm
♦ To secure the securing straps for the fuel tank, only
bolts with loose washers must be used. This will
stop the securing straps from being twisted out of
position when tightening the bolts.
Filler neck to body 8 Nm + 90°

Exhaust system ⇒ page 348
Fitting wheels ⇒ Running gear; Rep. gr. 44 ; Specified torque for
mounting wheels

7 Repairing fuel supply system (Golf,

Golf Plus, Scirocco, Eos)
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of crimp-type or screw-type clips is not permis‐
sible.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.

⇒ page 178 .
Observe crash fuel shut-off ⇒ page 213 .
Removing and installing fuel delivery unit ⇒ page 214 .
Removing and installing fuel gauge sender G ⇒ page 216
Checking fuel pump ⇒ page 217 .
7.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ 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.
7.2 Crash fuel shut-off

Function
Crash fuel shut-off system reduces the risk of a vehicle burning
in event of a crash in that the fuel pump is switched off. The sys‐
tem also improves the starting characteristics of the engine. When
door is opened, the fuel pump is activated for 2 seconds to build
up pressure in the fuel system.
When opening fuel system:
Observe safety precautions ⇒ page 178 .
7. Repairing fuel supply system (Golf, Golf Plus, Scirocco, Eos) 213
7.3 Removing and installing fuel delivery

unit (Golf Plus, Golf, Scirocco, Eos)
Note
After removing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

Removing:
Caution
Condition:
• The fuel tank must not be more than 3/4 full. This ensures
that the fill level is below the flange of the fuel delivery unit.
Note
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 178 .
♦ Observe rules for cleanliness ⇒ page 213 .
♦ Assembly overview - fuel tank ⇒ page 183 .

72 ; Removing and installing bench seat .

fuel delivery unit.
WARNING

off connection.
– Pull off connector -arrow-.
– Pull fuel lines -1- and -2- off the flange.
Note

– Open locking ring using key - T10202- and raise flange slightly.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Installing:
– Renew seal.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Press sealing flange down against spring pressure, and move

sealing flange to installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Tighten sealing flange.
• Specified torque: 110 Nm
– Reconnect supply line-1- (black).

– Reconnect fuel return line -2- (blue or blue marking).
– Reconnect connector -arrow-.

– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.
Further assembly is performed in the reverse order of removal.
During this procedure, observe the following:
♦ Observe installation position of fuel feed line to auxiliary heater

⇒ Auxiliary heater; Rep. gr. 82 ; Fuel feed Thermo Top V .
♦ The -arrow- on the cover points forwards.
7.4 Removing and installing fuel gauge

sender G
Removing:
– Remove fuel delivery unit ⇒ page 214 .

– Pull fuel gauge sender - G- slightly to side and upwards at the

same time.
– If the sender cannot be released in this way, the retaining tabs

-arrows- must also be pushed to the side slightly.
– Note colour co-ordination of cables for reinstallation.
– Release electrical connectors -1 to 3- and pull them off. Then

bend back locking lugs of connectors.
Installing:
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
– Install fuel delivery unit ⇒ page 214 .
7.5 Checking fuel pump
Note

equipment required
♦ Pressure gauge - VAS 6550-

♦ Remote control - V.A.G 1348/3A-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
♦ Multimeter - V.A.G 1715-
♦ Measuring container, capacity: 2 litres
7.5.1 Checking function and voltage supply

Test conditions:
• Battery voltage at least 11.5 V.
• Fuse for Fuel pump control unit - J538- OK.
• Fuel pump control unit - J538- OK.

Test sequence
Note
Function of fuel pump is checked using final control diagnosis.
– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Switch ignition on.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .
– Press right arrow button on display up to final control diagnosis

for fuel pump electronics.
The fuel pump must now run slowly up to maximum speed.
Note
The fuel pump runs very quietly.

If fuel pump does not run:
– Pull connector off fuel pump control unit - J538- .
– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
fuel delivery unit.
– First check that the connector -arrow- is fitted securely by pull‐

ing the connector without pressing the catch. If connector was
not inserted correctly, repeat functional check of fuel pump.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.
WARNING

off connection.
– Pull fuel lines -1- and -2- off the flange.
Note


– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective, renew fuel delivery unit ⇒ page 214 .

7.5.2 Checking fuel pressure
WARNING

off connection.
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release fuel line.
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- and -VAS 6550/2- .
– Make sure that drain tap is closed and cut-off taps are open.
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
• Specification: 4.0 to 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 222 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
If no fault is found:
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
If specification is not obtained
– Check fuel pressure upstream of fuel filter; proceed as follows:
– Pull fuel supply line -arrow- off fuel filter.
– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
– Start engine and run at idling speed.
– Slowly close cut-off tap -A-. Pressure must rise to at least

7.0 bar. When 7.0 bar is reached, open shut-off tap again im‐
mediately.
Note
It may take several minutes until the fuel pressure increases.
If pressure has risen:

– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
tive. Renew fuel filter.
If pressure does not rise:
7.5.3 Checking holding pressure

• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 221 .
Test sequence
pressure.
– Watch pressure drop on pressure gauge. Pressure must re‐
main above 3.0 bar for 10 minutes.
If the pressure drops further:
pressure.

– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure does not drop now:
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
– Check fuel pipe to high-pressure pump for leaks.

– Renew high-pressure pump ⇒ page 315 .
If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel supply line to fuel filter for leaks.
If no fault is found on the fuel line:
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:
– Connect pressure tester - VAS 6550- between fuel filter and

fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
pressure.
– After pressure has built up, close cut-off tap -A-.

– Watch pressure drop on pressure gauge. Pressure must re‐
If the pressure drops:
– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 214 .
If the pressure does not drop:
– Pressure retention valve in fuel filter is OK, pressure limiting
valve in fuel filter is defective. Renew fuel filter.
7.5.4 Checking fuel delivery rate
Note
When driving characteristic problems occur when the fuel tank is

a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
4 filled tank or less.

fuel delivery unit.

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
unit for damage.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal clamp in the engine
compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
WARNING

off connection.
fuel with a cloth.
Note

adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a
measuring container.
WARNING
Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold container
in front of open connection of pressure tester.
– Operate remote control - V.A.G 1348/3A- . Then slowly close

shut-off tap -arrow- until a pressure of 4 bar is displayed on
pressure gauge. From this point on do not move position of
shut-off tap.
– Drain measuring container.
– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump.
– Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm3/60 s
**) Voltage at fuel pump with engine not running and pump run‐
ning.
Reading example:
During the test a voltage of 10.5 volts is measured. This equates
to a minimum delivery rate of approx. 1200 cm3/60 s.
– Check fuel lines for possible restrictions (kinks) or blockages.
– Remove cap from fuel filler neck and repeat check. If fuel de‐
livery rate is now reached, check fuel tank breather.
If reading again does not match specification:
– Check fuel filter (proceed as follows):
WARNING

off connection.


shut-off tap.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
– Renew fuel delivery unit.
If the fuel delivery rate has been attained but a fault is still sus‐
pected in the fuel supply system (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 227 .
7.5.5 Checking current consumption

fuel delivery unit.

ing the connector without pressing the catch. The connector
can cause a fault if it has not been fitted correctly.
unit for damage.

– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Start engine and run at idling speed.
– Measure current draw of fuel pump.
• Specification: max. 9 amps (Eos, Golf, Golf Plus,Scirocco).
• Specification: max. 10 amps (Passat).
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:


8 Repairing fuel supply (Passat)
Note

clamp-type clips.
sible.
spring-type clips.
Observe safety precautions when working on fuel supply system

⇒ page 178 .
Removing and installing fuel delivery unit ⇒ page 230 .
Removing and installing fuel gauge sender - G- ⇒ page 233
Checking fuel pump ⇒ page 235 .

mantling.
toolboxes).
move the vehicle.

Function
8. Repairing fuel supply (Passat) 229


unit
Note

Removing:
Caution
Condition:
Note
♦ Drain fuel tank with fuel extractor - VAS 5190- .

♦ Note safety precautions ⇒ page 178 .
♦ Observe rules for cleanliness ⇒ page 229 .

72 ; Removing and installing bench seat .

fuel delivery unit.
WARNING

off connection.

– Release fuel line -2- and pull it off fuel delivery unit flange
-3-.
Note
♦ Make sure all components are mounted in the correct position.

– Open locking ring using wrench - T10202- and raise flange

slightly.
– Take fuel delivery unit flange as far as possible out of the
opening in the fuel tank.
– Pull seal out of opening.

– Release and separate plug-in connector -2-.

– Release suction line of suction-jet pump -arrow- and pull it off.
– Take delivery unit out of fuel tank through the opening.
Note
♦ If pump unit is to be renewed, old pump unit must be drained

before disposal.
♦ Observe relevant disposal regulations.
Installing:
Note
Make sure all components are mounted in the correct position.
– Renew seal.
– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
– Attach suction line of suction-jet pump -arrows- and click in

place.
– Reconnect plug-in connector -2-.
– Check whether flange -1- is correctly seated on fuel delivery

unit.

– Push flange downwards against spring force and move flange

into installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Tighten sealing flange.
– Attach connector -1-.

– Attach fuel lines -2-.
– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.
During this procedure, observe the following:
♦ Observe installation position of fuel feed line to auxiliary heater

⇒ Auxiliary heater; Rep. gr. 82 ; Fuel feed Thermo Top V .
♦ The -arrow- on the cover points forwards.
Torque setting
Locking ring 110 Nm

sender G
Removing:

– Pull fuel gauge sender - G- slightly to side and upwards at the

same time.
– If the sender cannot be released in this way, push the securing

tabs -arrows- to the side slightly.
– Note colour assignment of cables for re-installation.
– Release and pull off connectors -1…3- and bend back the
locking hooks of connectors.
Installing:
– Connect connectors -1…3-. Note colour assignment.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
Torque setting
Locking ring 110 Nm

8.5 Checking fuel pump
Note

equipment required



Test conditions:
• Battery voltage at least 11.5 V.
• Fuse for Fuel pump control unit - J538- OK.
Test sequence
Note
– Connect Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Switch on ignition.
– Press one after the other in the display the buttons for Vehicle
trol diagnosis .

Note

– Pull connector from fuel pump control unit - J538- .

– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
Fitting locations.
Voltage supply OK:
fuel delivery unit.
– Check that connector -arrow- is fitted securely by pulling con‐
nector without pressing catch. If connector was not inserted
correctly, repeat functional check of fuel pump.
WARNING

off connection.

– Release fuel lines -2- and pull them off fuel delivery unit flange
-3-.
– Check contacts on plug and on fuel delivery unit for damage.
Note


connected.
– Renew fuel delivery unit ⇒ page 230 .

WARNING

off connection.
fuel with a cloth.
Note
Press in securing ring to release fuel line.

pressure.
– Read off fuel pressure on pressure gauge.
If the specification is exceeded:
– Pressure limiting valve in fuel delivery unit is defective.
Note
Pressure limiting valve and fuel filter are integrated in fuel delivery
unit and cannot be renewed individually.

– Fuel pump is defective; renew fuel delivery unit ⇒ page 230 .


Test sequence
pressure.
– Observe pressure drop on pressure gauge. Pressure must re‐
pressure.
– After pressure has built up, close shut-off tap -B- of pressure
flow.
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.

– Check fuel line leading to fuel tank for leaks.
If the fuel line is found to be OK:
– Open fuel delivery unit flange -1- ⇒ page 230 .

– Check that all hose connections are connected.
– Renew fuel delivery unit.

Note


fuel delivery unit.
– Check that connector -1- is fitted securely by pulling connector

without pressing catch. The connector can cause a fault if it
has not been fitted correctly.

– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
WARNING

off connection.
fuel with a cloth.

Note

WARNING
Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold container
in front of open connection of pressure tester.

shut-off tap.

to outputs -1- and -5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
Then:
– Operate remote control for 60 seconds, whilst measuring volt‐
age at fuel pump.

– Compare delivered quantity of fuel with specification.

ning.
Reading example:
livery rate is now reached, check fuel tank breather
⇒ page 268 .
– Remove fuel delivery unit and check filter strainer for dirt.
If no fault is detected:
– Check current draw of fuel pump ⇒ page 242 .
If no fault is detected:
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):

fuel delivery unit.

– Check that connector -1- is fitted securely by pulling connector

without pressing catch. The connector can cause a fault if it
has not been fitted correctly.

5565- .
– Start engine and allow to idle.
• Specification: max. 10 amps (Passat).
Note
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.


9 Repairing fuel supply (Tiguan)
Note

clamp-type clips.
sible.
spring-type clips.

⇒ page 178 .
Removing and installing fuel delivery unit (Tiguan) ⇒ page 245 .
Removing and installing fuel gauge sender - G- (Tiguan)
⇒ page 247
Removing and installing suction-jet pump (Tiguan) ⇒ page 248
Removing and installing fuel gauge sender 2 - G169- (Tiguan)
⇒ page 251 .
Checking fuel pump (Tiguan) ⇒ page 253 .
Removing and installing fuel pump control unit - J538- (Tiguan)
⇒ page 251

mantling.
toolboxes).
♦ When the system is open, do not work with compressed air or
move the vehicle.

Function


unit (Tiguan)
Note

9.3.1 Removing
Caution
Condition:
Note
Drain fuel tank with fuel extractor - VAS 5190- .

coding.
9. Repairing fuel supply (Tiguan) 245


WARNING
Fuel system is under pressure! Wear eye protection and pro‐

tective gloves to avoid injuries and skin contact. Wrap a cloth
around the connection before loosening hose connections.
Then release pressure by carefully pulling hose off connection.
– Check that the connector is fitted securely by pulling the con‐

nector without pressing the catch.
Note
Check contacts of connectors for damage.
– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).
– Release connector -arrow- at fuel pump control unit - J538-

and pull off using assembly tool - T10118- .

– Lift delivery unit slightly and remove seal out of opening in fuel
tank.

– Release fuel hoses at delivery unit -arrows- and pull delivery

unit out of fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
9.3.2 Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
♦ Fuel hoses are allocated to respective unions.

♦ Ensure plug-in connectors are secured properly by pulling.
♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender - G- is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of flange for fuel delivery unit: tab
-1- must point in direction of travel. The fuel delivery unit flange
can only be installed in this position.
Torque setting
Locking ring 110 Nm

sender - G- (Tiguan)
♦ Welding wire (2 mm thick)

– Bend 80 mm long welding wire as shown.

Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connector of wiring for fuel gauge sender -2- and dis‐
connect it.
– Press welding wire -1- in direction of -arrow- into recess be‐

neath sender.
– At the same time, push fuel gauge sender -2- from guides in
direction of -arrow-.
Installing
– Insert fuel sender into guides on fuel delivery unit and press
downwards until it engages.
– Attach connector and ensure secure engagement.
9.5 Removing and installing suction-jet

pump (Tiguan)

Note
♦ In the case of the Tiguan, fuel must be pumped from the area
of fuel gauge sender 2 - G169- , to the fuel pump with a suction-
jet pump due to the shape of the fuel tank.
♦ The fuel delivery unit must first be removed to remove the
suction-jet pump.
♦ Checking is only necessary when the engine stops due to lack
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
9.5.1 Removing
– Remove cover on left (as seen looking in direction of travel) of
fuel gauge sender 2 - G169- .
nector without pressing the catch. The connector can cause a
fault if it has not been fitted correctly.
– Pull connector -1- off left flange.


– Lift flange slightly and remove seal out of opening in fuel tank.
– Pull flange together with fuel gauge sender 2 - G169- out of
fuel tank.
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Also check suction-jet pump for any dirt.
9.5.2 Installing
Caution
When installing do not bend fuel gauge sender 2 - G169- float

arm.
– Insert flange together with fuel gauge sender 2 - G169- into

fuel tank. The lug on the flange points in direction of travel.
– Place fuel lines in right chamber of fuel tank ensuring they are
not kinked.
– Place a new flange seal dry into aperture in fuel tank and
moisten inside (contact to flange) with fuel.
– Make sure fuel gauge sender 2 - G169- ⇒ page 206 is installed
in correct position.
– Make sure that oil seal is in correct position.
– Tighten locking ring using wrench - T10202- .
– Attach connector -1- and check it is secured properly by pull‐

ing.


sender 2 - G169- (Tiguan)
– Removing and installing suction-jet pump (Tiguan)
⇒ page 248
♦ Welding wire (2 mm thick)
– Bend 80 mm long welding wire as shown.
Dimension -a- = 10 mm
Dimension -b-: 70 mm
Removing
– Release connectors for lines for fuel gauge sender 2 - G169-
-2- and pull off.
– Press welding wire -1- in direction of -arrow- into recess be‐

neath sender.
– At the same time, push fuel gauge sender 2 - G169- -2- from
guides in direction of -arrow-.
Installing
the following:
– Insert fuel gauge sender 2 - G169- into guides and press down
until it engages.
– Attach connector and ensure secure engagement.
9.7 Removing and installing fuel pump con‐

trol unit - J538- (Tiguan)
Note
The fuel pump control unit - J538- is installed on the fuel tank.

♦ Commercially available flat-bladed screwdriver (blade width
120 mm)

Fuel pump control unit - J538- fitting location

1 - Bracket for fuel pump control unit - J538-
2 - Fuel pump control unit - J538-
3 - Connector
Removing
– Remove cover on right (as seen looking in direction of travel)
from fuel delivery unit.
– Check that 5-pin connector -1- is fitted securely by pulling

connector without pressing catch. The connector can cause a
– Pull off connector -1-.
– Slide screwdriver -2- into bracket recess -1- directly above

plug.
– Swivel screwdriver in -direct of arrow-.
– Press screwdriver downwards in direction of -arrow-, pulling

control unit out of bracket by the plug at same time.
nector without pressing the catch. The connector can cause a
– Pull connector off control unit.
Installing

– Connect connector -3- to control unit -2- and check secure

engagement (by trying to pull it off).
– Slide control unit -2- into bracket -1- until it engages.
Further installation is carried out in reverse order of removal.
9.8 Checking fuel pump (Tiguan)
Note

equipment required


Check function and voltage supply ⇒ page 254 .
Checking holding pressure ⇒ page 256 .
Checking fuel delivery rate ⇒ page 257 .
Checking current draw ⇒ page 260 .

• Battery voltage at least 11.5 V
• Fuse for fuel pump on fuse holder OK ⇒ Current flow diagrams,
Test sequence
Note
– Connect Vehicle diagnostic tester as follows:

– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Switch on ignition.
– Press one after the other in the display the buttons for Vehicle
trol diagnosis .

Note

Note


connector without pressing catch. If connector was not inser‐
ted correctly, repeat functional check of fuel pump.
– Now pull off connectors -1-.

– Connect multimeter - V.A.G 1715- to contacts -1- and -5- of
adapters - VAS 5565- .
– Actuate fuel pump with final control diagnosis.
• The voltage must rise up to battery voltage during final control
diagnosis.
Fitting locations.
Voltage supply OK:
connected.

Test conditions:
• Function of fuel pump has been checked ⇒ page 254 .
Test sequence
WARNING

off connection.
– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.


pressure.
– Renew left flange with pressure limiting valve, suction jet pump
and fuel filter.
Note
Pressure limiting valve and fuel filter are integrated into fuel gauge
sender 2 - G169- with suction-jet pump and cannot be renewed
individually.
– Repeat test.

Test sequence
pressure.
– Observe pressure drop on pressure gauge. Pressure must re‐
pressure.

– After pressure has built up, close shut-off tap -B- of pressure
flow.
Note
Search for leak on engine side. Repeat holding pressure check.

This time, close shut-off tap -A- to check whether leak actually is
on engine side.

– Check fuel line leading to flange for leaks.
If no fault is detected on »external« fuel lines, search for leak in
fuel tank. Proceed as follows:
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak.
– Renew left flange with pressure limiting valve and fuel filter.
Repeat pressure retention test. If leak is still present, non-re‐
turn valve in fuel pump leaks, renew fuel delivery unit
⇒ page 245 .
Note

Test conditions
• Voltage supply OK.
Note



– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
– Pull off supply line (metal coupling) -2- and catch escaping fuel
with a cloth.
Note


WARNING
Danger of spray when shut-off tap is opened. Wear eye pro‐

tection and protective clothing to avoid injuries and skin con‐
tact. Hold container in front of open connection of pressure
tester.

shut-off tap.

to contacts -1- and -5- of adapters - VAS 5565- .
– Operate remote control for 60 seconds, whilst measuring volt‐
age at fuel pump.

– Compare delivered quantity of fuel with specification.

ning.
Reading example:
livery rate is now reached, check fuel tank breather
⇒ page 271 .
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak. Check sieve in fuel delivery
unit and fuel tank for coarse soiling.
– Renew left flange with pressure limiting valve and fuel filter.
Repeat delivery rate check. If fuel delivery is still insufficient,
fuel pump defective, renew fuel delivery unit.
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):



5565- .
– Start engine and allow to idle.
• Specification: max. 16 amps
Note
♦ If the fuel system malfunction is intermittent, the check can be
performed during a road test, but a 2nd person is necessary.


10 Repairing electronic power control

(EPC)
Removing and installing accelerator pedal module ⇒ page 262
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ Openings -A- for re‐
lease tool.
❑ To remove, remove
dash panel cover and
pedal cluster cover.
accelerator pedal mod‐
ule ⇒ page 262
3 - 10 Nm
4 - Protective cap
10.2 Removing and installing accelerator

pedal module

♦ Release tool - T10238-
♦ Release tool - T10240- (for right-hand drive)
Procedure
– Remove pedal cluster cover.
– Pull connector off accelerator module.
– Pull off protective cap in upper area of accelerator module.
– Remove securing bolt.
– To remove accelerator module, push release tool - T10238-
(for right-hand drive models) -T10240- into openings provided
to stop.
– Pull out accelerator pedal module vertically.
Install in reverse order of removal.
Specified torque for securing bolt: 10 Nm.
10. Repairing electronic power control (EPC) 263

11 Activated charcoal filter system (Golf,

Golf Plus, Eos, Scirocco)
Assembly overview (Golf, Golf Plus, Eos, Scirocco) ⇒ page 264
Checking fuel tank breather (Golf, Golf Plus, Eos, Scirocco)
⇒ page 265
Note

clamp-type clips.
spring-type clips.
11.1 Assembly overview (Golf, Golf Plus, Eos, Scirocco)
1 - Activated charcoal filter

❑ Location: on right in en‐
gine compartment.
2 - Pressure retention valve
with connecting hose
3 - Connection hose
❑ From fuel tank
4 - 10 Nm
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ Fitting location: behind
intake manifold
❑ Valve closed with igni‐
tion switched off
❑ When engine is warm,
valve is activated
(pulsed) by engine con‐
trol unit - J623- .
6 - Connection hose
❑ To intake manifold
7 - Bracket
❑ For activated charcoal
filter.
8 - Breather hose
9 - Sealing grommet

11.2 Checking fuel tank breather (Golf, Golf

Plus, Eos, Scirocco)
♦ Hand operated vacuum pump - VAS 6213-
♦ Adapter set - V.A.G 1318/17-

• Ignition must be switched off.
Test sequence
– Pull off breather line -1-. To do this, press release button.
– Then connect hand vacuum pump - VAS 6213- using adapter
set - V.A.G 1318/17- to the activated charcoal filter line.
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
If vacuum builds up:
– Check breather hose ⇒ Item 8 (page 264) on activated char‐
coal filter for soiling and clean if necessary.
If vacuum does not build up:
– Hold breather fitting ⇒ Item 8 (page 264) closed and operate
vacuum pump again several times. Vacuum must build up.
If vacuum does not build up:
– Renew activated charcoal filter.

mantling.
11. Activated charcoal filter system (Golf, Golf Plus, Eos, Scirocco) 265

toolboxes).
move the vehicle.

12 Activated charcoal filter system (Pas‐

sat)
Checking fuel tank breather ⇒ page 268 .
Note

clamp-type clips.
♦ Spring-type clip pliers - VAS 5024A- are recommended for in‐
stallation of spring-type clips.

❑ Location: in rear right
wheel housing.
2 - Pressure retention valve
with connecting hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
ter solenoid valve 1 -
N80-
5 - Breather line
❑ From activated charcoal
filter
tion switched off
valve will be activated
trol unit
7 - Connection hose
8 - Nut
❑ 10 Nm
12. Activated charcoal filter system (Passat) 267

12.2 Checking fuel tank breather


Test sequence
– Pull off breather line -1-; to do this, press in release button.
– Connect hand vacuum pump - VAS 6213- to breather line as

shown.
– Seal breather hole in activated charcoal filter -arrow- and op‐

erate vacuum pump again several times. Vacuum must build
up.
– If vacuum does not build up, renew activated charcoal filter.


mantling.
toolboxes).
♦ When the system is open, do not work with compressed air or
move the vehicle.
12. Activated charcoal filter system (Passat) 269

13 Activated charcoal filter system (Ti‐

guan)
Assembly overview (Tiguan) ⇒ page 270
Checking fuel tank breather (Tiguan) ⇒ page 271
Note

clamp-type clips.
♦ Spring-type clip pliers - VAS 5024A- are recommended for in‐
stallation of spring-type clips.
13.1 Assembly overview (Tiguan)

❑ Location: in rear right
wheel housing.
2 - Connection hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
ter solenoid valve 1 -
N80-
5 - Breather line
❑ From activated charcoal
filter
tion switched off
valve will be activated
trol unit
7 - Connection hose
8 - Nut
❑ 10 Nm

13.2 Checking fuel tank breather (Tiguan)


Test sequence
– Pull off bleeder line -1-. To do this, press release button.
– Connect hand vacuum pump - VAS 6213- to breather line as

shown.
– Pull off hose -1- at activated charcoal filter.
– Seal breather hole in and connecting pieces at activated char‐

coal filter -arrows- and operate vacuum pump again several
times. Vacuum must build up.
– If vacuum does not build up, renew activated charcoal filter.
13. Activated charcoal filter system (Tiguan) 271


mantling.
toolboxes).
♦ When system is open, avoid working with compressed air and
moving vehicle.

21 – Turbocharging/supercharging
1 Exhaust turbocharger
Note
♦ Secure all hose connections with hose clips which conform to

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ It is recommended that spring-type clips should be installed
using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed and do not rev up immediately. This ensures that
the turbocharger is fully primed with oil.
Assembly overview - turbocharger ⇒ page 273 .

Removing and installing turbocharger ⇒ page 277 .
Removing and installing compressor housing and turbine housing
⇒ page 282 .
Checking turbocharger vacuum unit ⇒ page 286 .
Removing and installing vacuum unit for turbocharger
⇒ page 288 .
Adjusting vacuum unit for turbocharger ⇒ page 290 .
1.1 Assembly overview - turbocharger

Part I ⇒ page 275
Part II ⇒ page 276
1. Exhaust turbocharger 273

274 Rep. gr.21 - Turbocharging/supercharging

1.2 Part I
1 - Turbocharger with exhaust

manifold
⇒ page 277
compressor housing
and turbine housing
⇒ page 282 .
❑ Checking turbocharger
vacuum unit
⇒ page 286 .
vacuum unit for turbo‐
charger ⇒ page 288 .
❑ Adjusting vacuum unit
for turbocharger
⇒ page 290 .
Specified torques:
❑ Securing bolts for vac‐
uum unit to turbocharg‐
er: 20 Nm.
❑ Lock nut to vacuum unit
rod: 10 Nm.
2 - O-ring
❑ Renew
3 - Turbocharger air recircula‐
tion valve - N249-
4 - 11 Nm
5 - Connection hose
6 - Intake connecting pipe
7 - 10 Nm
8 - Connection hose
10 - Charge pressure control solenoid valve - N75-
11 - 10 Nm
12 - Connection hose
14 - Bracket
❑ At coolant line.

1.3 Part II
1 - Oil supply pipe

❑ A modified oil supply
pipe is installed as of
model year 2009 ►
❑ Note specified torques
⇒ Item 20 (page 277) .
2 - 8 Nm
3 - 8 Nm
4 - Coolant pipe
5 - Bracket
6 - 8 Nm
7 - O-ring
❑ Renew
8 - 8 Nm
9 - 20 Nm
10 - 8 Nm
11 - Coolant pipe
12 - Seal
❑ Renew
13 - 8 Nm
14 - Oil return pipe
15 - 8 Nm
16 - Turbocharger with ex‐
haust manifold
⇒ page 277
compressor housing
and turbine housing ⇒ page 282 .
Note
♦ The studs need to be renewed as

well as the securing nuts.
♦ Screw studs into cylinder head
until they project only by 25 mm.
17 - Seal
❑ Renew
18 - 25 Nm
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste.
Note


19 - Bracket
20 - Banjo bolt
❑ Renew
Note
A modified oil supply pipe is instal‐

led as of model year 2009 ►. Note
differing specified torques.
Specified torques:
❑ Banjo bolt on cylinder block 30 Nm
❑ Banjo bolt on valve timing housing 20 Nm.
21 - Seal
❑ Renew
1.4 Removing and installing turbocharger


Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger is
not enough. To prevent this from causing further damage, per‐
form the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
Note

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.

– Clamp off coolant hoses to turbocharger using hose clamps
from -3094- .


N249- .
– Pull hoses -1- off intake connecting pipe for turbocharger.

– Pull connector -2- off charge air pressure sender - G31- with
intake air temperature sender 2 - G299- and remove securing
bolts -3-.
– Press retaining clips -1- outwards and pull pressure pipe -2-
upwards.
– Then pull pressure pipe -2- off turbocharger.
– Unscrew securing bolts -arrows- and remove heat shield from

turbocharger.

– Detach coolant hoses -1- from coolant pipes.

– Unscrew securing bolts -2- and remove coolant pipe -3-.
ing; Rep. gr. 87
Note

– Unbolt securing nuts at turbocharger -arrows-.

– Unclip wiring -1- from catalytic converter.
– Disconnect connectors -2-.

– Unscrew securing nuts -3- and remove seal.
– Remove securing bolts -arrows- from heat shield and pull

shield off exhaust manifold in direction of -arrow-.
– Remove securing bolts -1- for oil supply pipe -3-.

– Unscrew banjo bolt -2- from cylinder block and remove oil
supply pipe.
Note
From model year 2009 ► banjo bolt -2- is secured on valve timing
housing.
– Unscrew securing bolt -4- and remove bracket -5-.
– Unscrew securing bolts -1- for oil return pipe -2- and remove
pipe.
Note
The alternator must only be loosened if the securing nuts have

inner drive splines.
– Loosen alternator ⇒ Electrical system; Rep. gr. 27 ; Removing

and installing alternator .
– Remove all securing nuts -1- from exhaust manifold and pull
bracket -3- off studs.
– Remove exhaust manifold together with turbocharger -2- from
cylinder head.
Installing
Note
♦ The studs need to be renewed as well as the securing nuts.

♦ Screw studs into cylinder head until they project only by
25 mm.
– Fit turbocharger together with exhaust manifold and new gas‐

ket to cylinder head.

– Tighten securing nuts to 25 Nm in sequence as specified.

Perform further installation in reverse order, paying attention to
the following:
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Specified torques:
Assembly overview - part I, turbocharger ⇒ page 275 .
Assembly overview - part II, turbocharger ⇒ page 276 .
Assembly overview - catalytic converter and add-on parts
⇒ page 348
– Top up coolant if necessary ⇒ page 159 .
– Attach coolant hoses -2- to engine cover panel and press en‐
gine cover panel downwards.
– Tighten securing bolts -1- for engine cover panel to 8 Nm.
1.5 Removing and installing compressor

housing and turbine housing
Note
Please use a suitable repair kit for the following work sequence
⇒ Electronic Parts Catalogue (ETKA) .

♦ Engine bung set - VAS 6122-

♦ Hot air blower - V.A.G 1416-
Removing
– Remove turbocharger ⇒ page 277 .
– Checking turbocharger vacuum unit ⇒ page 286 .
– Seal all openings in turbocharger -arrows- with suitable plugs
from engine bung set - VAS 6122- .
– Remove circlip -1- using screwdriver -2-.

– Pull threaded rod -3- off stud.
Caution
To prevent damage to the exhaust manifold, always use alu‐

minium protective jaws -1- for the vice!

– Clamp exhaust manifold -2- in vice as shown in illustration.
– Use a waterproof pen to mark position of bolt -arrow- relative

to compressor housing.
– Unscrew securing nut -1- of clamp -2-, and remove clamp.
Caution
If the turbine housing is still tightly secured to the compressor

housing after the clamp -2- has been removed:
• Do not use leverage tools!
• Always use the hot air blower - V.A.G 1416- to loosen the
connection in order to prevent the centring pin on the tur‐
bine housing from being damaged.
If the compressor housing is still tightly secured to the turbine

housing due to deposits:
– Using hot air blower - V.A.G 1416- , apply heat evenly all
around the connection point between the compressor housing
and the turbine housing for about 2 minutes.
– Carefully remove compressor housing upwards.
If the centring pin -arrow- is sheared off or damaged, the turbo‐

charger must be renewed together with the exhaust manifold.
Caution
Place compressor housing on workbench as shown in illustra‐

tion to prevent any damage to the turbine wheel.
Do not use compressed air to clean the compressor housing!

– Clean compressor housing all around -arrows- using, for ex‐

ample, brake cleaner and sandpaper (220 to 1000 grade).
– Remove exhaust manifold from vice.
Installing
Caution
To prevent damage to the exhaust manifold, always use alu‐

minium protective jaws -1- for the vice!
– Clamp new exhaust manifold -2- in vice as shown in illustra‐

tion.
– Fit compressor housing onto turbine housing.
Ensure that the centring pin -1- of the turbine housing engages in
the hole -2- of the compressor housing.

– Using a feeler gauge -1-, measure gap -arrow- between com‐

pressor housing and turbine housing.
The gap must measure ≤ 1.2 mm around the entire circumfer‐
ence.
– Fit new clamp around both flanges.
Note
♦ The threaded shank may bend slightly when the securing nut
is tightened to 9 Nm. This is normal and not critical.
♦ Therefore, a new clamp with a new threaded shank must al‐
ways be used when assembling.
– Align clamp so that centre of stud is flush with marking

-arrow- on compressor housing.
– Tighten new securing nut -1- of clamp -2- to 9 Nm.
– Apply light hammer blows alternately all around the clamp

-arrow-
in order to ensure proper seating of the clamp.
– Then, tighten securing nut again to 9 Nm.
– Push threaded rod -1- of vacuum unit onto stud -2-.

– Push new retaining ring -3- into groove in stud.
– Adjust vacuum unit for turbocharger ⇒ page 290 .
– Install turbocharger ⇒ page 277 .
1.6 Checking vacuum unit for turbocharger

Removing and installing vacuum unit for turbocharger
⇒ page 288 .
Adjusting vacuum unit for turbocharger ⇒ page 290 .


Conditions for testing

♦ The hose from the turbocharger via the charge pressure con‐
trol solenoid valve - N75- to the vacuum unit must have
through-flow and be free of leaks.
♦ Charge pressure control solenoid valve - N75- OK.
Procedure
– Unscrew bolts -arrows- and remove heat shield for turbo‐
charger.
– Pull hose -arrow- off vacuum unit.

– Place hose -2- of hand-operated vacuum pump - VAS 6213-

onto vacuum unit connection.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.
– Operate hand vacuum pump - VAS 6213- repeatedly.
Caution
Excessive pressure may damage the vacuum unit.

The pressure must remain at or below 800 mbar!
Note
The illustration shows the installation position with the turbo‐

charger removed.
– Observe operating rod -1- of turbocharger vacuum unit.

♦ The operating rod must move from approx. 300 mbar.
♦ At approx. 800 mbar, the operating rod must reach the end of
the adjustment travel.
– Vent hand-operated vacuum pump - VAS 6213- -arrow A-.

♦ The operating rod must move in the opposite direction.
Note
Check the movement sequence of the operating rod in the entire

adjustment range. It must move continuously and smoothly.
Assembly is performed in the reverse order of removal.

Specified torque of heat shield for turbocharger: 8 Nm
1.7 Removing and installing vacuum unit for

turbocharger
Removing
– Detach coolant hose -2- from engine cover panel.


– Unscrew bolts -arrows- and remove engine cover panel.
– Remove air filter housing ⇒ page 305 .

charger.
– Unscrew bolts -2- and remove retaining clip -1-.
– Pull connector -3- off charge air pressure sender - G31- .

– Release catches -arrows- and pull air pipe first off throttle valve
module - J338- and then off turbocharger.
– Lay hoses at air pipe to side.
– Unscrew bolt -4- and remove crankcase breather hose from

turbocharger -arrow- and lay it to side.
Note
The positions labelled -1, 2, 3- should be disregarded.

– Clamp off coolant hoses using hose clips - 3094- as illustrated.

– Remove bolts -1, 3, 4, 5-.
– Pull coolant lines off turbocharger and lay to side.
Note
The position labelled -2- should be disregarded.
– Unscrew bolts -2- and -3-, then remove retaining plate.
Note
The positions labelled -1- and -4- should be disregarded.
– Lever off securing clip -2- and pull threaded piece -1- of oper‐
ating rod off operating lever pin -3-.
Note
– Remove hose -2- from turbocharger vacuum unit.

– Unscrew bolts -1- and remove turbocharger vacuum unit -3-.
Installing
– Install new securing clip for operating rod.
Note
Ensure securing clip seats correctly in the pin groove.
– Adjusting vacuum unit for turbocharger ⇒ page 290 .
1.8 Adjusting vacuum unit for turbocharger


equipment required

♦ Pressure regulating valve - VAS 6342-
♦ Turbocharger tester - V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS 6341-
♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

Procedure
– Detach coolant hose -2- from engine cover panel.
– Unscrew bolts -arrows- and remove engine cover panel.
– Remove air filter housing ⇒ page 305 .

charger.
– Unscrew bolts -2- and remove retaining clip -1-.
– Pull connector -3- off charge air pressure sender - G31- .

– Release catches -arrows- and pull air pipe first off throttle valve
module - J338- and then off turbocharger.
– Lay hoses at air pipe to side.

– Unscrew bolt -4- and remove crankcase breather hose from

turbocharger -arrow- and lay it to side.
Note
The positions labelled -1, 2, 3- should be disregarded.
– Clamp off coolant hoses using hose clips - 3094- as illustrated.

– Remove bolts -1, 3, 4, 5-.
– Pull coolant lines off turbocharger and lay to side.
Note
– Unscrew bolts -2- and -3-, then remove retaining plate.
Note
The positions labelled -1- and -4- should be disregarded.
– Remove hose -2- from turbocharger vacuum unit.
Note
– Connect test and measuring instruments together as illustra‐

ted and connect to connection “II” of turbocharger tester -
V.A.G 1397A- and to turbocharger vacuum unit.

– Close lever -1- on pressure regulating valve - VAS 6342- .

– Move slide ring -2- of hand-operated vacuum pump - VAS
6213- in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position “II”.
– Operate hand vacuum pump - VAS 6213- several times until
a pressure of approx. 800 mbar is attained.
Caution
Excessive pressure may damage the vacuum unit.

The pressure must remain at or below 800 mbar!
– Vent hand-operated vacuum pump - VAS 6213- -arrow A- so

that rod of charge pressure control vacuum unit in turbocharg‐
er can move freely.
– Repeat process 5 times.
– Secure universal dial gauge bracket - VW 387- to turbocharger
as illustrated.
– Secure dial gauge - VAS 6341/1- with flat pickup - VAS 6341/4-
to universal dial gauge bracket - VW 387- .
– Set dial gauge - VAS 6341/1- to 1 mm pretension at 0 bar.
– Turn graduated scale of dial gauge - VAS 6341/1- to “0”.
a pressure of 385 mbar is attained on turbocharger tester -
V.A.G 1397A- .

Specification on dial gauge - VAS 6341/1- : 1 mm stroke.
Note
♦ If specification is not attained, loosen lock nut -4-.

♦ Lever up securing clip -2- and pull threaded piece -1- off op‐
erating lever pin -3-.
♦ Turn threaded piece on operating rod until specification is at‐
tained. Position threaded piece onto operating lever pin to
perform check.
♦ If the bore of the threaded piece does not fit onto the pin in this
position, the threaded piece may be rotated one-half turn in
either direction.
♦ Secure threaded piece with securing clip -2- to operating lever
pin and tighten lock nut -4-.
Checking adjustment of vacuum unit

– Set dial gauge - VAS 6341/1- to 1 mm pretension at 0 bar.
Measurement 1:
a pressure of 750 … 800 mbar is attained on turbocharger
tester - V.A.G 1397A- .
– Reduce pressure to 375 mbar on pressure regulating valve -
VAS 6342- .
– Read stroke on dial gauge - VAS 6341/1- and make a note.
– Reduce pressure to 0 mbar on pressure regulating valve - VAS
6342- .
pressure of 375 mbar is attained on turbocharger tester -
V.A.G 1397A- .
– Calculate average by adding values “1” and “2” and dividing
sum by 2.
Specification: 1 mm
Measurement 2:
a pressure of 750 … 800 mbar is attained on turbocharger
tester - V.A.G 1397A- .
– Reduce pressure to 475 mbar on pressure regulating valve -
VAS 6342- .
– Reduce pressure to 0 mbar on pressure regulating valve - VAS
6342- .
– Turn graduated scale of dial gauge - VAS 6341/1- to 0.
pressure of 475 mbar is attained on turbocharger tester -
V.A.G 1397A- .
– Calculate average by adding values “1” and “2” and dividing
sum by 2.
Specification: 5 mm

– If specifications are not attained, repeat adjustment proce‐

dure.
Assembly is performed in the reverse order of removal.

2 Charge air system
Note
♦ It is recommended that spring-type clips should be installed

using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Charge air system must be free of leaks.
Assembly overview - charge air system ⇒ page 297

Removing and installing intake manifold charge air cooler
⇒ page 298
2.1 Assembly overview - charge air system
1 - Auxiliary radiator for charge

air system
❑ Remove cooler to re‐
move ⇒ page 165 .
in the Tiguan and Pas‐
sat ⇒ page 169 .
2 - O-ring
3 - Upper coolant hose
❑ Connection diagram for
coolant hoses
⇒ page 158
6340-
5 - Connecting pipe
6 - Coolant hose
❑ To expansion tank
7 - Protective sleeve
8 - Coolant hose
❑ To turbocharger
9 - Coolant hose
10 - Intake manifold
⇒ page 310
11 - Seal
12 - Sealing strip
❑ Make sure it is properly seated when installing the charge air cooler.
2. Charge air system 297

13 - Charge air cooler

❑ To remove, remove intake manifold ⇒ page 310 .
14 - 7 Nm
❑ When installing, first evenly tighten by hand and then tighten to specified torque.
15 - Connecting pipe
16 - Coolant hose
17 - Coolant hose
18 - 10 Nm
19 - 10 Nm
20 - Coolant circulation pump - V50-
21 - Bracket
22 - 20 Nm
23 - Coolant pipe
24 - 10 Nm
25 - Lower coolant hose
2.2 Removing and installing intake manifold

charge air cooler
♦ Support bridge - 3250-

Removing
– Remove intake manifold ⇒ page 310 .
– Unscrew securing bolts for charge air cooler in specified se‐
quence -A- to -F-.
– Pull charge air cooler out of intake manifold.
Installing
Note
Charge air cooler is installed into intake manifold using a work‐

shop press.
– Push sealing strip -1- in -direction of arrow- onto edge of

charge air cooler.
– Check new gasket is seated correctly on intake manifold.
– Push charge air cooler into intake manifold to stop.
Do not tilt charge air cooler when installing it.
Note
♦ Align intake manifold on table of workshop press.

♦ The housing of the charge air cooler -1- must be horizontal.
♦ Use, for example, a wooden block as a base.
– Position support - 3250- centrally on charge air cooler.

– Carefully lower ram of workshop press until housing of charge
air cooler -1- lies on intake manifold -2-.
– Screw securing bolts in evenly until bolt heads make contact.

– Tighten securing bolts to 7 Nm in sequence specified -A- to
-F-.
– Install intake manifold ⇒ page 310 .
Further installation is performed in the reverse order of removal.
2. Charge air system 299

24 – Mixture preparation - injection

1 Injection system
Assembly overview - parts l and II, intake manifold ⇒ page 300 .
Assembly overview - part I, intake manifold ⇒ page 302 .
Assembly overview - part II, intake manifold ⇒ page 303 .
Assembly overview - fuel rail with injectors ⇒ page 304 .
Assembly overview - air filter ⇒ page 304 .
Removing and installing air filter ⇒ page 305 .
Removing and installing throttle valve module - J338-
⇒ page 306
Cleaning throttle valve module - J338- ⇒ page 309 .
Removing and installing intake manifold ⇒ page 310 .
Assembly overview - high-pressure pump ⇒ page 311 .
Checking fuel pressure sender - G247- ⇒ page 312 .
Removing and installing high-pressure pump ⇒ page 315
Removing and installing injectors ⇒ page 319 .
Renewing Teflon seal and support washer on injector
⇒ page 322
Safety precautions ⇒ page 325 .
Comply with rules for cleanliness ⇒ page 213 .
Technical data ⇒ page 327 .
General notes on injection
♦ The engine control unit - J623- is capable of self-diagnosis.
Before carrying out repairs and for fault finding, first read event
memory. Also the vacuum hoses and connections must be
checked (unmetered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel
pump is activated for 2 seconds to build up pressure in the fuel
system.
1.1 Assembly overview - parts l and II, intake manifold
300 Rep. gr.24 - Mixture preparation - injection

1. Injection system 301

1.2 Assembly overview - part I, intake manifold
1 - Connection hose
2 - Fuel line
❑ High pressure
Specified torques for union
nuts.
To high-pressure pump:
18 Nm.
To lower part of intake mani‐

fold: 20 Nm
3 - 8 Nm
4 - Clamp
5 - Fuel hose
❑ Low pressure
❑ To high-pressure pump
6340-
7 - Union
❑ For fuel supply.
❑ For crankcase ventila‐
tion.
9 - 8 Nm
10 - O-ring
❑ Not available as sepa‐
rate part
❑ In event of damage, re‐
new complete compo‐
nent
11 - Union
❑ On valve timing housing.
12 - Pressure pipe
❑ From turbocharger
❑ On camshaft housing.
❑ On air filter housing.
❑ On activated charcoal filter.

17 - Activated charcoal filter solenoid valve 1 - N80-

19 - Clamp
❑ On turbocharger.
1.3 Assembly overview - part II, intake manifold
1 - Retaining clip
2 - 7 Nm
3 - Pressure pipe
4 - O-ring
❑ Renew
5 - Charge air pressure sender
- G31- with intake air tempera‐
ture sender 2 - G299-
6 - 5 Nm
7 - 7 Nm
8 - Adapter
9 - Intake manifold
⇒ page 310
10 - Intake manifold pressure
sender - G71-
11 - 5 Nm
12 - 20 Nm
13 - Throttle valve module -
J338-
⇒ page 306
❑ Cleaning ⇒ page 309
❑ If renewed, erase learnt
values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
14 - Seal
❑ Renew
15 - Fuel pressure sender - G247- , 22 Nm
❑ Checking fuel pressure sender - G247- ⇒ page 312 .
16 - 80 Nm
17 - Intake manifold lower part
To remove:
❑ Remove throttle valve module - J338- ⇒ page 306 .
❑ Removing and installing intake manifold ⇒ page 310 .

18 - Seal
❑ Renew
19 - 20 Nm
1.4 Assembly overview - fuel rail with injectors
1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Spring element
❑ Renew each time after
removing lower part of
intake manifold.
❑ Ensure proper seating
on injector.
3 - Injector, cylinder 4 - N33-
❑ Injector, cylinder 1 -
N30-
N31-
N32-
❑ With Teflon seal and
support washer.
❑ After removing injector,
Teflon seal and support
washer must be re‐
newed ⇒ page 322 .
injectors ⇒ page 319 .
4 - Intake manifold lower part
❑ To remove, remove and
install throttle valve
module - J338- and in‐
take manifold
⇒ page 306 .
1.5 Assembly overview - air filter

Removing and installing air filter ⇒ page 305 .

1 - Air filter upper part

2 - 1.6 Nm
❑ Tighten with torque
screwdriver - VAS
6494- .
3 - 1.6 Nm
screwdriver - VAS
6494- .
4 - Bracket
5 - Filter element
6 - Bonded rubber bush, 8 Nm
❑ With captive bolt.
7 - Sealing strips
8 - Air filter lower part
⇒ page 305
9 - Rubber mounting
10 - Intake connecting pipe
❑ With cover.
11 - 3 Nm
12 - Intake air guide
13 - 1.6 Nm
screwdriver - VAS
6494- .
hose clip pliers - VAS 6340- .
15 - Intake hose
16 - Vacuum hose
❑ From camshaft housing.
1.6 Removing and installing air filter

Removing
– Press catches -arrows- and remove cover -1- from intake
manifold.

– Pull intake connecting pipe out of intake air duct.

– Pull spring-type clip -2- together with intake hose off turbo‐
charger.
– Pull vacuum hose -1- from air filter housing.

– Remove securing bolt -2- and pull air filter housing upwards
off locating pins -3-.
Installing
the following:
– Push air filter housing onto locating pins -3- from above.
– Tighten securing bolt -2- to 8 Nm.
– Fit vacuum hose -1- onto air filter connection.
1.7 Removing and installing throttle valve

module - J338-

Removing
– Pull oil dipstick out
– Detach hoses -1- and -2- from pressure pipe.

– Pull connector off charge air pressure sender - G31- with in‐
take air temperature sender 2 - G299- -4- and remove securing
bolts -3-.
– Press retaining clips -1- outwards and slightly pull pressure

pipe -2- upwards.
– Then pull pressure pipe -2- off turbocharger.

– Pull connector -1- off throttle valve module - J338- .

– Unscrew securing bolts -2- and remove throttle valve module
-3- from intake manifold.
Installing
– Place new sealing ring into groove in intake manifold.
– Position throttle valve module -3- together with adapter -2- and
securing bolts -1- on intake manifold -4-.

– Fit connector -1- onto throttle valve module -3-.
Note
Before installing, lightly coat O-rings on turbocharger and in pres‐

sure pipe with engine oil.
– Fit pressure pipe -2- onto turbocharger.

– Press pressure pipe -2- onto throttle valve module.
The retaining clips -1- must engage audibly.

– Tighten bolts -3- of retaining clips to 7 Nm.

– Fit connector onto charge air pressure sender - G31- with in‐
take air temperature sensor 2 - G299- .
– Press hoses -1- and -2- into retainers on pressure pipe.
– Attach coolant hoses -2- on engine cover panel and fit engine
cover panel onto camshaft housing.
If a new throttle valve module was installed:
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
1.8 Cleaning throttle valve module - J338-
Note
♦ If a new engine control unit - J623- is installed the throttle valve

module must be adjusted. Adaptation must be performed only
with a new or cleaned throttle valve module, because soiling
or coking at the end stop of the throttle valve can lead to in‐
correct adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.
– Remove throttle valve module ⇒ page 306 .

– Open throttle valve by hand and lock in open position using a
suitable object (e.g. wood or plastic wedge) -arrow-.
WARNING
Acetone is highly inflammable. Please comply with the acci‐

dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and

– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.
1.9 Removing and installing intake manifold

Removing

– Remove throttle valve module ⇒ page 306 .

– Press release button -2- and pull fuel supply line off.

– Clamp off coolant hoses -4- using hose clamps, up to 40 mm in
diameter - 3093- .
– Pull off coolant hoses -4- after first opening the retaining clips.
– Unclip lines -2- from bracket.
– Unscrew securing bolts -3- of intake manifold.
– Unclip the other lines.
– Remove intake manifold.
Installing
Specified torque of securing bolts for intake manifold: 20 Nm.
Specified torques and installation sequence for charge air cooler
⇒ page 297
1.10 Assembly overview - high-pressure

pump
WARNING

6 bar).
approx. 6 bar. The appropriate procedure is described in the
chapter on releasing pressure in the high-pressure section
⇒ page 179 .

1 - 20 Nm
2 - Union
❑ Low pressure
6340- .
4 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
5 - Union nut, 18 Nm
❑ Observe safety precau‐
tions ⇒ page 178 .
❑ Counterhold when loos‐
ening connection to
high-pressure pump.
6 - Union
7 - High-pressure pump with
fuel pressure regulating valve -
N276-
8 - Roller tappet
❑ Lightly coat with engine
oil when installing.
9 - O-ring
❑ Renew
❑ Lightly coat with engine
oil when installing.
1.11 Checking fuel pressure sender - G247-


♦ Open ring spanner with 3/8" drive, width across flats 27 mm

(flared spanner)
♦ Pressure sensor tester - VAS 6394/1-

♦ Adapter - VAS 6394/2-
♦ Test adapter - VAS 5570-
Procedure
WARNING

6 bar).
⇒ page 179 .
– Remove fuel pressure sender - G247- -1- using an open ring

spanner.
– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐

gine oil and screw into fuel rail. Specified torque: 22 Nm.

– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 22 Nm.
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS
6394/2- .
– Connect fuel pressure sender -1- and electrical connector of

fuel pressure sender using test instrument adapter - VAS
5570- .

– Switch on tester - VAS 6394/1- to do this, press button -A- once

briefly.
Note
♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the pressure tester - VAS 6394/1- reading is not 0 bar, carry
out a zero point procedure ⇒ operating instructions .
– Connect vehicle diagnostic tester to diagnostic connection.

– Switch ignition on.
– Press following buttons on display of diagnostic tester one af‐
ter the other:
Vehicle self-diagnosis
Self-diagnosis ►
01 - Engine electronics ►
011 - Measured values ►
– Select measured value block 2 4 7 and confirm with Q .

The actual fuel pressure value is shown in display zone 2, meas‐
ured by the fuel pressure sender - G247- .
– Start engine.
– Compare the displayed pressure of pressure tester - VAS
6394/1- with the displayed actual value on 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- .
WARNING

6 bar).
⇒ page 179 .
– Repeat the test with the new fuel pressure sender - G247- and
compare both measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.
1.12 Removing and installing high-pressure

pump

Removing
WARNING

6 bar).
⇒ page 179 .
– Separate fuel supply line -arrow-.


– Pull connector -1- and fuel supply line -2- off high-pressure
pump.
Note
Catch escaping fuel in a cloth.
– Remove cable guide -2-.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
– Loosen union nuts -1- and -3- of high-pressure line.
– Unscrew securing bolts -1- evenly.
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.

– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
shaft housing.
Installing
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.
Note
♦ Moisten high-pressure pump roller tappet with clean engine

oil.
♦ The high-pressure pump O-ring must be renewed.
– Slide roller tappet -1- into camshaft housing.
– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
– Screw in securing bolts -1- by hand until bolt heads are seated
on flange.
– Tighten securing bolts -1- evenly until flange is seated on
camshaft housing.

– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install cable guide and tighten securing bolt -2- to 8 Nm.
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten union nuts -1- and -3- of high-pressure line to 18 Nm.
– Secure fuel supply line -2- and connector -1- to high-pressure

pump.
– Reconnect fuel supply line -arrow-.
1.13 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 325 .

Note
Teflon seal on injector must be renewed each time after removing

injector ⇒ page 322 .

♦ Tool set - T10133-
Removing
– Remove lower part of intake manifold ⇒ page 303 .
– Press O-ring upwards by hand as shown, and remove it from
injector.
– Screw slide hammer - T10133/3- to puller - T10133/15- .

– Then insert puller - T10133/15- into groove -arrow- on injector.
– Pull injector out by tapping carefully.

Installing
– Thoroughly clean injector holes in cylinder head using nylon

brush - T10133/4- .
– Check plastic support washer for damage, renew if necessary
⇒ page 322 .

– Renew spring element -arrow- and Teflon seal each time the
injectors are removed ⇒ page 322 .
– Renew O-rings between injector and lower part of intake mani‐
fold and moisten slightly with clean engine oil.
Note
Do not oil or grease the Teflon seal on the injector.
– Push injector into cylinder head bore to stop by hand.
Note
The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
– Ensure correct position of injectors in cylinder head.

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 302 .
1.14 Renewing Teflon seal and support

washer on injector
♦ Tool set - T10133-
Procedure
Renewing Teflon seal
– Remove lower part of intake manifold ⇒ page 303 .
– Remove injectors ⇒ page 319 .
– Clean injector carefully.
– Carefully cut open seal with a knife as shown -arrow-. Avoid
contact between knife blade and valve body under all circum‐
stances.

– Remove old seal and clean seal groove in area of seal

-arrow-. Remove coking deposits using a brass wire brush.
– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
assembly sleeve - T10133/6- (knurled end faces seal -1-),
gently slide seal onto assembly cone - T10133/5- as far as
possible.
– Turn assembly sleeve - T10133/6- around (knurl no longer

points to seal), and push seal -1- to end of assembly cone -
T10133/5- .
– Now place assembly cone - T10133/5- with seal onto injector
from front. Slide seal further onto injector using assembly
sleeve - T10133/6- .
The seal is not yet seated in its groove.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
– Slide seal into annular groove by hand.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

– Pull off calibrating sleeve - T10133/7- again.

– Now push calibrating sleeve - T10133/8- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibrating sleeve - T10133/8- again.
Now the Teflon seal has correct installation dimensions.

Renewing support washer
– Remove O-ring -3-.
– Cut support washer -2- open with a small pair of side cutters
and remove it.
– Pull spring element -1- off injector and replace with retaining
plate - T10133/12- .
– Place new support washer -1- onto assembly cone -

T10133/13- and position onto injector as shown.
– Slide support washer -1- into first groove -arrow- on injector
using calibration sleeve - T10133/17- (knurled side points to
injector).

– Now turn calibration sleeve - T10133/17- around (knurled side

no longer points to injector). Slide calibration sleeve over sup‐
port washer -1- in direction of -arrow- to stop on retaining plate
- T10133/12- .
– Pull calibrating sleeve - T10133/17- down again.
The support washer now has correct installation dimensions.
– Now remove retaining plate - T10133/12- and fit a new spring

element -1- instead. Fit a new O-ring -3- in front of support
washer -2-.
Note
The Teflon seal -arrow- must not be oiled to install injector.
– Install injectors ⇒ page 319 .

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 302 .
Further installation is carried out in reverse order of removal.
1.15 Safety precautions
WARNING
Fuel system is under pressure! Wear protective goggles and

off connection.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ For safety reasons, fuse No. 27 must be removed from fuse
holder on left under dash panel before opening fuel system.
Otherwise fuel pump will be activated by driver door contact
switch.
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.

Caution

sitions.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils.
– To do this, fit puller - T10094 A- on ignition coil with final output

stage -arrow- ⇒ page 363 .
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism, and pull off
connector.
– When installing ignition coil for final output stage, slide con‐
nector on until it audibly engages.

– Fit puller - T10094 A- as shown ⇒ page 363 .

– Press ignition coil with output stage into cylinder head in di‐
rection of -arrow-.

mantling.
toolboxes).
move the vehicle.
1.17 Technical data

Engine code CAXA, CMSB
Idling check
Idling speed7) rpm 600 … 800
Engine control unit - J623-
System Motronic MED 17
Governed speed rpm From approx. 5600-6000
7) Not adjustable.

2 Engine control unit - J623-

Removing and installing engine control unit - J623- (Golf ► 2008,
Eos) ⇒ page 328
Removing and installing anti-theft engine control unit - J623-
(Golf ► 2008, Eos ► 10.2008) ⇒ page 329
Removing and installing engine control unit - J623- (Golf 2009 ►)
⇒ page 331
Removing and installing anti-theft engine control unit - J623- (Golf
2009 ►, Eos 11.2008 ►, Scirocco 10.2008 ►, Passat 2011►)
⇒ page 333
Removing and installing engine control unit - J623- (Golf Plus)
⇒ page 335
Removing and installing anti-theft engine control unit (Golf Plus,
Touran) - J623- ⇒ page 336 .
Removing and installing engine control unit - J623- (Passat ►
2006) ⇒ page 339
Removing and installing anti-theft-secured engine control unit -
J623- (Passat 2006 ►) ⇒ page 340
Removing and installing engine control unit - J623- (Scirocco)
⇒ page 341
Removing and installing anti-theft engine control unit - J623-
(Scirocco 09.2008 ►) ⇒ page 342
Removing and installing engine control unit - J623- (Tiguan)
⇒ page 344
Removing and installing anti-theft engine control unit - J623- (Ti‐
guan) ⇒ page 345
2.1 Removing and installing engine control

unit - J623- (Golf ► 2008, Eos)
If you wish to renew the engine control unit, connect the ⇒ vehicle
diagnostic tester and perform the guided function “Renewing con‐
trol unit”.
Removing
– Remove securing bolts -1- and remove cover plate -2-.

– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then press engine control unit out of retainer
-in direction of arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install cover plate for connectors.

– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit using ⇒ vehicle diagnostic tester
in “Guided functions”.
– Read event memory, rectify any faults and then clear ⇒ Ve‐
hicle diagnostic tester event memory “Guided Fault Finding”.
– Install plenum chamber bulkhead ⇒ General body repairs;
– The readiness code must be generated if the event memory
has been cleared.
– Read control unit event memory again.
2.2 Removing and installing anti-theft en‐

gine control unit - J623- (Golf ► 2008,
Eos ► 10.2008)
♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

trol unit”.
Removing
2. Engine control unit J623 329

– Remove wiper arms and plenum chamber cover: ⇒ Electrical

system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.

– Lever up protective housing using screwdriver -A- and in side‐

wards motion pull off bracket -arrow-.
– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Now release connector on engine control unit and pull off con‐
nector.
Installing
– Fit connector to engine control unit and lock connector in po‐
sition.
– Push engine control unit onto bracket.
– Press catch -1- against engine control unit.

– Select “guided functions” in the vehicle diagnosis, testing and
information system - VAS 5051B- .
– Perform vehicle identification and select engine code.
– Perform function “Renew control unit”.
– Push protective housing onto bracket.
– Tighten new shear-head bolts -1- evenly until heads shear off.
has been cleared.

unit - J623- (Golf 2009 ►)
trol unit”.

Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Press retaining frame down in -direction of arrow- and remove
engine control unit.
– Push connector locking devices in direction of -arrow-, and pull

connectors off.
Installing
– Fit connectors to engine control unit and slide locking devices

onto stop in direction of -arrow-.
– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐


gine control unit - J623- (Golf 2009 ►,
Eos 11.2008 ►, Scirocco 10.2008►,
Passat 2011►)
trol unit”.
Removing
Golf 2009, Eos 11.2008, Scirocco 10.2008
– Unscrew shear-head bolts -arrows- using pliers.
– Insert screwdriver between both locking plates -arrow-.

– Carefully press screwdriver in direction of -arrow- and bend
retaining bow -1- upwards at the same time.

– Bend retaining bow -1- in direction of -arrow- until it can be

pulled off connectors.

connectors off.
Installing

– Fit retaining bow -1- onto connectors and press it in direction

of -arrow-.
– Guide pin -2- to stop into hole on valve timing housing.

– Secure retaining bow with shear-head bolts to engine control

unit -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.
Golf 2009, Eos 11.2008, Scirocco 10.2008
screen wiper system; Removing and installing wiper arms.

unit - J623- (Golf Plus)
trol unit”.
Removing
– Loosen securing bolts -arrows- of control unit cover.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

nector.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
– Tighten securing bolts -arrows- to 10 Nm.

has been cleared.

gine control unit - J623- (Golf Plus)

♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

trol unit”.
Removing
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

nector.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.

– Install cover of protective housing.
– Tighten new shear-head bolts -arrows- evenly until heads

shear off.
has been cleared.


unit - J623- (Passat 2006 ►)
trol unit”.
Removing
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.


-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .

gine control unit - J623- (Passat 2006 ►)
trol unit”.
♦ Grip pliers
Removing
cover
– Unscrew bolts -1-.
– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.


– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- in retaining

frame until it engages.
– Tighten the retaining frame.

-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

unit - J623- (Scirocco)
trol unit”.
Removing



connectors off.
Installing


gine control unit - J623- (Scirocco ►
09.2008)
trol unit”.

Removing
– Remove shear-head bolts -arrows- using pliers and remove

locking clips.

connectors off.
Installing


– Fit the two locking clips over the connector and secure with
new shear-head bolts -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.

unit - J623- (Tiguan)
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051 B- and car‐
ry out the guided function “Renew control unit”.
Removing
cover
– Pull connector (if there is one) -1- off heated windscreen con‐
trol unit - J505- .
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.

– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.

-2- inwards.
– Attach connector (if there is one) -1- to heated windscreen
control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .

gine control unit - J623- (Tiguan)
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051B- and carry
out the guided function “Renew control unit”.
♦ Grip pliers
Removing
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
– Remove plenum chamber cover ⇒ General body repairs, ex‐
cover.

– Unscrew bolts -1-.

– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.

– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- in retaining

frame until it engages.
– Tighten the retaining frame.


-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
Assembly overview - catalytic converter and add-on parts

⇒ page 348
Assembly overview - silencer with mountings (Golf, Golf Plus,
Scirocco) ⇒ page 351
Assembly overview - silencer with mountings (Passat 2006 ►)
⇒ page 352
Assembly overview - silencer with mountings (Passat 2011 ►)
⇒ page 353
Assembly overview - silencer with mountings (Eos) ⇒ page 354
Assembly overview - silencer with mountings (Tiguan)
⇒ page 355
Removing and installing centre and rear silencers (Golf, Golf Plus,
Scirocco, Eos) ⇒ page 355 .
Detaching centre and rear silencers (Passat) ⇒ page 357
Detaching centre and rear silencers (Tiguan) ⇒ page 359
Mounting position and specified torque of the clamping sleeve
⇒ page 360
1.1 Assembly overview - catalytic converter and attachments
348 Rep. gr.26 - Exhaust system

1 - 10 Nm
❑ First tighten all securing
bolts by hand when in‐
stalling.
2 - Lambda probe after catalyt‐
ic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
3 - Seal
❑ Renew
4 - Exhaust pipe
5 - Double clamp, 25 Nm
❑ Installation position and
specified torque
⇒ page 360
❑ For separate replace‐
ment of centre and rear
silencers
❑ Tighten bolted connec‐
tions evenly.
6 - 25 Nm
❑ Renew
7 - Mounting
8 - 25 Nm
9 - 25 Nm
❑ Renew
10 - Exhaust pipe
❑ With decoupling element.
❑ Do not bend flexible joint more than 10°. Otherwise, it can be damaged.
❑ Removing and installing compressor housing and turbine housing ⇒ page 282 .
Note

12 - Bracket
13 - Heat shield
14 - 25 Nm
❑ Renew
Note

1. Removing and installing parts of exhaust system 349


❑ Coat studs of exhaust manifold with high-temperature paste.
15 - 25 Nm
❑ Renew
Note
Use clips when installing

⇒ page 350 .
16 - Catalytic converter with exhaust pipe
Note
Use clips when installing.

❑ Installing catalytic converter ⇒ page 350
17 - 23 Nm
❑ Renew
18 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
Install catalytic converter.

– Slide clips onto bracket in -direction of arrow-.
The lips of the clips face downwards.
– Tighten new securing bolts to 25 Nm.

1.2 Assembly overview - silencer with mountings (Golf, Golf Plus, Scirocco)
1 - Mounting
2 - 25 Nm
3 - Bracket
sition
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers
⇒ page 355
5 - 25 Nm
6 - Bracket
sition
7 - Mounting
8 - Rear silencer
9 - Mounting

1.3 Assembly overview - silencer with mountings (Passat 2006 ►)
1 - Exhaust pipe with front si‐

lencer
2 - Mounting
3 - Double clamp
❑ For repair cases
specified torque
⇒ page 360
tion ⇒ page 352
❑ During production, front
and rear silencers are
installed as a single
component. In case of
repair, the front and rear
silencers are supplied
individually and with a
double clamp for con‐
necting.
❑ Cut through exhaust
pipe with e.g. pneumatic
sabre saw - V.A.G
1523A- or chain pipe
cutter - VAS 6254- at
right angles at the sepa‐
rating point
⇒ page 352 .
4 - Bracket
sition
5 - Mounting
6 - Bolt
❑ 25 Nm
7 - Exhaust pipe with rear si‐
lencer
❑ Align after mounting ⇒ page 357 .
8 - Bracket
Separating point on exhaust pipe
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
– Cut through exhaust pipe at separating point -arrow 2- at right

angles e.g. with pneumatic sabre saw - V.A.G 1523A- or chain
pipe cutter - VAS 6254- .
– Position repair double clamp at markings.
– Align rear silencer -1- so that dimensions -a- are identical.

1.4 Assembly overview - silencer with mountings (Passat 2011 ►)
1 - Clamping sleeve
specified torque
⇒ page 360
tion ⇒ page 357
❑ During production, front
and rear silencers are
installed as a single
component. In case of
repair, the front and rear
silencers are supplied
individually and with a
double clamp for con‐
necting.
sabre saw - V.A.G
rating point
⇒ page 357 .
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
2 - Exhaust pipe with front si‐
lencer
3 - Clamping sleeve
specified torque
⇒ page 360
❑ Comply with instruc‐
tions for alignment of
rear silencer
⇒ page 357
❑ During production, front and rear silencers are installed as a single component. In case of repair, the
front and rear silencers are supplied individually and with a double clamp for connecting.
❑ Cut through exhaust pipe with e.g. pneumatic sabre saw - V.A.G 1523A- or chain pipe cutter - VAS 6254-
at right angles at the separating point ⇒ page 357 .
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
4 - Bracket
5 - Bolt
❑ 25 Nm
6 - Mounting
7 - Exhaust pipe with rear silencer
❑ Align after mounting ⇒ page 357 .
8 - Mounting

9 - Bracket
10 - Bolt
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel suspension, rear .
❑ 90 Nm + 90°
❑ Renew after each removal
❑ M12 x 1.5 x 110
1.5 Assembly overview - silencer with mountings (Eos)
1 - Mounting
2 - 25 Nm
3 - Bracket
sition
4 - Centre silencer
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In case
of repair, the centre and
rear silencers are sup‐
plied separately, includ‐
ing a repair double
clamp for purposes of
connection.
sabre saw - V.A.G
rating point
⇒ page 355 .
5 - 25 Nm
6 - Bracket
sition
7 - Mounting
8 - Rear silencer
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In case
of repair, the centre and rear silencers are supplied separately, including a repair double clamp for pur‐
poses of connection.
❑ Cut through exhaust pipe with e.g. pneumatic sabre saw - V.A.G 1523A- or chain pipe cutter - VAS 6254-
at right angles at the separating point ⇒ page 355 .
9 - Mounting

1.6 Assembly overview - silencer with mountings (Tiguan)
1 - Exhaust pipe with centre

and rear silencers
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
2 - Bolt
❑ 20 Nm
3 - Bracket
4-
❑ 25 Nm
❑ Qty. 2
5 - Bracket
6 - Mounting
7 - Bolt
❑ 25 Nm
❑ Qty. 2
8 - Bracket
9 - Bolt
❑ 25 Nm
❑ 2 on right and 2 on left
10 - Tunnel cross-piece
11 - Nut
❑ 25 Nm
❑ Qty. 4
1.7 Removing and installing centre and rear

silencers (Golf, Golf Plus, Scirocco,
Eos)
♦ 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-
or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure
– Cut through exhaust pipe at cutting point -arrow 2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position double clamp -4- centrally at side marks when instal‐
ling -1- and -3-.
– Install double clamp so that bolt ends do not protrude beyond

lower edge of double clamp -arrow-.
• Threaded connection faces to rear.
– Ensure correct mounting position and specified torque
⇒ page 360 .
– Align rear silencer free of stress ⇒ page 357 .
Torque settings
Component Nm
Double clamp 25

Aligning rear silencer (Golf, Golf Plus)

– Align rear silencer so that dimensions -a- are identical.
1.8 Detaching centre and rear silencers

(Passat)
or

Separating point on exhaust pipe
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
BlueMotion vehicles up to 10.2010

– Remove panelling of rear axle ⇒ Wheel suspension, rear;
Rep. gr. 42 ; Assembly overview: Attachments for subframe
of BlueMotion vehicles .
– Remove additional underbody panels on left and right ⇒ Body,
front; Rep. gr. 50 ; Additional underbody panels (BlueMotion)
- Assembly overview for vehicles up to 10.2010 .
BlueMotion vehicles from 11.2010
– Remove panelling of rear axle ⇒ Wheel suspension, rear;
Rep. gr. 42 ; Assembly overview: Attachments for subframe
of BlueMotion vehicles .
– Remove additional underbody panels on left and right ⇒ Body,
front; Rep. gr. 50 ; Additional underbody panels (BlueMotion)
- Assembly overview for vehicles from 11.2010 .
– Cut through exhaust pipe at separating point -arrow 2- at right
angles e.g. with pneumatic sabre saw - V.A.G 1523A- or chain
pipe cutter - VAS 6254- .
– Position double clamp for repair in middle of markings.
Align rear silencer.

– Align rear silencer -1- so that dimensions -a- are identical.
– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Nuts are below
⇒ page 360 .
– Aligning rear silencer free of stress ⇒ page 358
Torque setting
Double clamp ⇒ page 360

1.9 Detaching centre and rear silencers (Ti‐

guan)
or
Procedure
– Cut through exhaust pipe at separating point -2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position clamping sleeve centrally at side marks -1- and -3-
when installing.

– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
⇒ page 360 .
– Aligning rear silencer free of stress ⇒ page 360
Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
Torque setting
Double clamp ⇒ page 360
1.10 Installation position and specified torque

of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.

Clamp -A- with 2 individual clips.
Specified torque: 25 Nm.
Length: 95 mm
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Length: 88 mm
Installation dimensions -a- 8.5 mm (only for front clamp)

Installation dimension -a- for vehicles with marking -A- on front

exhaust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
3 - Securing nut
4 - Securing nut
a - Installation dimension
A - Marking
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right
Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.

28 – Ignition system
1 Repairing ignition system
General notes on ignition system
♦ The engine control unit - J623- is capable of self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ In some tests, a fault may be detected and stored by the en‐
gine control unit - J623- . Therefore, after completing all the
checks and repairs, read the event memory and clear it if nec‐
essary .
Assembly overview - ignition system ⇒ page 362 .
Removing and installing ignition coils with output stage
⇒ page 363 .
Safety precautions ⇒ page 364 .
Spark plug test data ⇒ page 365 .
1.1 Assembly overview - ignition system
1 - Connector
❑ Black, 4-pin.
❑ Release using assem‐
bly tool - T10118- .
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
⇒ page 363
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Connector contacts are
gold-plated.
4 - Knock sensor 1 - G61-
❑ Connector contacts are
gold-plated.
5 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
6 - Connector
❑ Black, 3-pin.
❑ For Hall sender - G40- .
362 Rep. gr.28 - Ignition system

7 - Hall sender - G40-

8 - O-ring
9 - 10 Nm
10 - Spark plug, 25 Nm
❑ Remove and install with spark plug socket and extension - 3122 B-
❑ Type and electrode gap ⇒ page 365 .
11 - Wiring guide
❑ Bolt to camshaft housing with 5 Nm torque.
12 - Earth cable
❑ Loosen or tighten only with ignition switched off.
13 - 10 Nm
❑ Loosen or tighten only with ignition switched off.
1.2 Removing and installing ignition coils

with output stage
Note
The ignition coil housings with output stages have been modified.
As a result, these ignition coils can only be removed and installed
with puller - T10094 A- . The previous puller - T10094- can con‐
tinue to be used if modified as described below.
1. Repairing ignition system 363

– Remove marked area -2- using suitable workshop equipment

to attain the new nominal dimension -B- of 18 mm.
– Add the letter A to the end of tool designation -1-.
Removing
– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism, and pull off
connector.
Installing
– Fit puller - T10094 A- on ignition coil with final output stage.
– Slide connector on ignition coil with output stage until it audibly
engages.
– Press ignition coil with output stage into cylinder head in di‐
rection of -arrow-.
1.3 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
364 Rep. gr.28 - Ignition system

– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage ⇒ page 363 .
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
1.4 Test data, spark plugs

Engine code CAXA, CMSB
Firing order 1-3-4-2
Spark plugs
VW part number 8) 101 905 626 B
Electrode gap 0.8 to 0.9 mm
Torque setting 25 Nm
Change interval ⇒ Maintenance ; Booklet ; Time or distance de‐
pendent additional work
8) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
1. Repairing ignition system 365

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Copyright © 2018 Volkswagen AG, Wolfsburg K0059101820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4 Fuel tank (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

1.1 Engine number

Engine code and engine number can be found on the sticker

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

1.2 Engine data

Engine code CAXA

Engine code CAXA CMSB

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Engine support - T40075- with adapters /1, /2, /3

1. Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 3

♦ Engine and gearbox support - VAS 6095-

♦ Hose clamp pliers - VAS 6340-

The battery earth must be disconnected for the remaining proce‐

4 Rep. gr.10 - Removing and installing engine

– Remove securing bolts -1- of engine cover panel.

Golf, Golf Plus, Eos, Scirocco

– Remove hose -3- from activated charcoal filter system sole‐

1. Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 5

– Release coolant hoses at heat exchanger -arrows- and pull

– Unscrew securing bolts -arrows- and remove heat shield from

– Unbolt securing nuts at turbocharger -arrows-.

– Remove securing bolts -arrows- of engine splash protection.

6 Rep. gr.10 - Removing and installing engine

– Release coolant hose -1- at auxiliary radiator for charge air

– Disconnect connectors -2-.

– Unbolt exhaust pipe together with flexible joint -arrows-.

1. Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 7

– Loosen securing bolts of double clamp -arrows- and pull ex‐

– Open all line guide fasteners -arrows-.

8 Rep. gr.10 - Removing and installing engine

– Disconnect pendulum support -arrows-.

Do not depress clutch pedal.

– Detach spring-type clips -2- and pull coolant hoses off.

– Remove bracket for coolant circulation pump - V50- from

The air conditioning system lines must not be opened.

– Secure air conditioner compressor to lock carrier.

1. Removing and installing engine (Golf, Golf Plus, Eos, Scirocco) 9

– Screw adapter - T40075/1- to stop into crankcase.

– Secure engine support - T40075- hand-tight to crankcase us‐

– Tighten all bolts on engine support - T40075- to 20 Nm.

10 Rep. gr.10 - Removing and installing engine

– Unbolt engine side of assembly mounting from above

– Unbolt gearbox side of assembly mounting from above

To remove securing bolts use a stepladder - VAS 5085- .