Engine Cuaa Repair Manual Eng

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Service

Workshop Manual
Arteon 2018 ➤, Arteon 2021 ➤,
Arteon Shooting Brake 2021 ➤,
Passat 2015 ➤, Passat 2019 ➤,
Passat Variant 2015 ➤,
Passat Variant 2019 ➤, Tiguan 2016 ➤
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA
288)
Engine ID
CUA
A
Edition 02.2021

Service Department. Technical Information


Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug 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.
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9


1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.7 Checking adjustment of assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.9 Renewing caps in cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Renewing caps in cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Contents i
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97


3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113


1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.5 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.5 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.4 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 192
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 199
3.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.5 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.6 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 205

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

ii Contents
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207


1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.3 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.4 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.5 Checking filling quality of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.6 Flushing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.4 Assembly overview - actuator for engine temperature regulation N493 . . . . . . . . . . . . . . . . 269
2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.8 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.9 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 283
2.10 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 283
2.11 Removing and installing coolant temperature sender 2 G802 . . . . . . . . . . . . . . . . . . . . . . 285
2.12 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 287
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
4.2 Assembly overview - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.3 Assembly overview – radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.5 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 330
4.6 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4.7 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4.8 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.3 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
1.4 Removing and installing turbocharger 1 control unit J724 . . . . . . . . . . . . . . . . . . . . . . . . . . 372
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
2.2 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
2.3 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . . . 379
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
2.5 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
2.6 Checking charge air cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395


1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
1.3 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

Contents iii
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417


3.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
3.2 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3.3 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
3.4 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
3.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 422
3.6 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
3.8 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
3.9 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
5.1 Assembly overview – intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
5.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
6.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 459
6.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
6.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
6.5 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 466
6.6 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . 467
6.7 Removing and installing charge air temperature sender ahead of charge air cooler G810 . . 469
6.8 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 469
6.9 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
6.10 Removing and installing control unit for NOx sender GX30 . . . . . . . . . . . . . . . . . . . . . . . . 471
6.11 Assembly overview - NOx sender control unit GX30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
6.12 Removing and installing control unit 2 for NOx sender GX46 . . . . . . . . . . . . . . . . . . . . . . 476
6.13 Removing and installing particle sensor G784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
9.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497


1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
1.1 Assembly overview – silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1.3 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
1.6 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
1.7 Assembly overview - front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
2.2 Removing and installing emission control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
2.3 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

iv Contents
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.1 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530


3.2 Assembly overview - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
3.3 Assembly overview - delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 535
3.4 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
3.5 Removing and installing front section of reducing agent supply line . . . . . . . . . . . . . . . . . . 542
3.6 Removing and installing delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . 557
3.7 Removing and installing injector for reduction agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 559
3.8 Removing and installing control unit for reducing-agent heater J891 . . . . . . . . . . . . . . . . 562
3.9 Assembly overview - injector for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
3.10 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
3.11 Removing and installing rear section of reducing agent supply line . . . . . . . . . . . . . . . . . . 574
3.12 Removing and installing filler pipe for reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . 576
3.13 Disconnecting reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
3.14 SCR - resetting learnt values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
4 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
4.1 Assembly overview – exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 584
4.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 586
4.3 Removing and installing exhaust gas temperature sender 2 G448 . . . . . . . . . . . . . . . . . . 592
4.4 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 594
4.5 Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 595
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
5.1 Assembly overview – exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 601
5.3 Removing and installing exhaust gas recirculation valve 1 GX5 . . . . . . . . . . . . . . . . . . . . 607
5.4 Removing and installing exhaust gas recirculation valve 2 GX6 . . . . . . . . . . . . . . . . . . . . 609
5.5 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
6 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
6.1 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
6.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616


1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
1.1 Assembly overview - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 621
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622

Contents v
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

vi Contents
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

00 – Technical data
1 Safety information
(VRL015255; Edition 02.2021)
⇒ r1.1 egulations for working on fuel supply”, page 1
⇒ m1.2 easures when working on vehicles with a start/stop
system”, page 2
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on the cooling system”, page
2
⇒ p1.5 recautions when working on the SCR system”, page 2
⇒ p1.6 recautions when working on exhaust system”, page 3

1.1 Safety regulations for working on fuel


supply
When working on the fuel system please note the following:

WARNING

Danger of scalding from very hot fuel.


♦ In extreme cases, the temperature of the fuel and the
fuel lines can reach 100 °C after the engine is switched
off. Allow the fuel to cool down before disconnecting the
lines - risk of scalding.
♦ Wear protective gloves.
♦ Wear protective goggles.

Risk of injury from highly pressurised fuel.


The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.

Danger of fire caused by escaping fuel


When the battery is connected and the driver door opens, the
door contact switch activates the fuel pump. Escaping fuel can
ignite and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.

1. Safety information 1
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.2 Safety measures when working on vehicles with a start/stop system


Risk of injury due to unexpected engine start
If the vehicle's start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury from unsecured test instruments and measuring
equipment
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test instruments and
measuring equipment on the rear seat.

1.4 Safety precautions when working on the cooling system


Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

1.5 Safety precautions when working on the SCR system


Risk of damage caused by reducing agent
If reducing agent gets onto trim panels and body components,
the reducing agent could crystallise after a while and in doing
so damage the surface.
– Make sure that no reducing agent gets onto the trim panels
or body components.
– If any reducing agent does get onto surfaces, remove it im‐
mediately using water and a cloth.

Risk of injury due to reducing agent


The reducing agent may cause eye and skin irritations as well
as injuries to the respiratory system and poisoning.

2 Rep. gr.00 - Technical data


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Wear protective goggles.


– Wear protective gloves.
– Always wear protective clothes.
– Make sure that a sufficient amount of fresh air is supplied. In
closed areas, switch on the exhaust gas extractor system.

WARNING

♦ Information concerning storage and disposal ⇒ Service‐


Net → Environmental protection → Workshop disposal!
Request country specific information from importer con‐
cerning storage and disposal.
Risk due to escaping reducing agent:
♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, it is necessary
to wait until automatic return of the reducing agent is
completed ⇒ page 3 .

Automatic return of reducing agent


• After the ignition has been switched off, the reducing agent
is returned from the metering line leading to the reducing
agent injector -N474- back to the reducing agent tank.
• Before any work is done in this area, it is necessary to wait
until all the reducing agent has been returned to the tank.
This can take up to 10 minutes after the ignition has been
switched off.
• Similarly, it is not permissible to disconnect the battery until
all the reducing agent has been returned to the tank, i.e. 10
minutes after the ignition is switched off ⇒ Electrical system;
Rep. gr. 27; Battery; Disconnecting and connecting battery.

1.6 Safety precautions when working on exhaust system


Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.
– Never open an exhaust gas temperature sender by cutting,
sawing or any other means.
Risk of injury due to hot condensate and particles in the ex‐
haust system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.

1. Safety information 3
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Risk of damage to damper 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.

4 Rep. gr.00 - Technical data


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Identification
⇒ n2.1 umber/engine data”, page 5

2.1 Engine number/engine data


♦ The engine number (“engine code” and “serial number”) is
located at the front at the joint between engine and gearbox
-arrow-.

♦ Additionally there is a sticker on the toothed belt cover (top)


with “engine code” and “serial number”.
♦ The engine codes have four characters, starting with the
letter “C”.
♦ The first 3 characters stand for the engine's cubic capacity
and mechanical structure. They are stamped into the cylin‐
der block together with the serial number.
♦ The fourth character denotes the engine's performance and
torque rating and depends on the engine control unit.

Note

♦ The 4-character engine code can be found on the type plate


(in versions for some countries only) as well as on the vehi‐
cle data sticker and the engine control unit.
♦ The fitting locations for vehicle data sticker (country-specif‐
ic) and identification plate are described in ⇒ Maintenance;
Booklet .

Codes CUAA
Exhaust emissions fulfil EU 6
Displacement l 1.968
Power kW at rpm 176/3500 to 4000
Torque Nm at rpm 500/1750 to 3000
Bore Diameter, mm 81.0
Stroke mm 95.5
Compression ratio 15.5
Fuel: acc. to DIN EN 590
Firing order 1-3-4-2
Exhaust gas recirculation yes
Exhaust gas temperature regulation yes
Balancer shafts yes
Charging Turbocharger
Charge air cooling yes

Volkswagen Technical Site: https://vwts.ru 2. Identification 5


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Codes CUAA
Lambda regulation 1 lambda probe
Diesel particulate filter with catalytic converter yes
SCR catalytic converter yes
Valves per cylinder 4

6 Rep. gr.00 - Technical data


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Repair instructions
⇒ f3.1 or cleanliness”, page 7
⇒ o3.2 bjects in engine”, page 7
⇒ c3.3 orrosion”, page 7
⇒ a3.4 nd attachment of lines”, page 8
⇒ r3.5 adiator and condensers”, page 8

3.1 Rules for cleanliness


Even slight soiling can cause faults. You must therefore comply
with the following cleanliness rules when working on the fuel
supply system, injectors or the turbocharger:
♦ Thoroughly clean all unions and surrounding areas before
disconnecting.
♦ Dry cleaned area thoroughly.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set -VAS 6122-.
♦ Place removed parts on a clean surface and cover them
over. Use lint-free cloths only.
♦ If repair work cannot be performed immediately, carefully
cover or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts
that have been stored outside of their packaging (e.g. in tool
boxes).
♦ If system is open, do not work with compressed air.
♦ Do not move the vehicle when the system is open.
♦ Protect disconnected electrical connectors from dirt and wa‐
ter, and reconnect them only when dry.
♦ The components must be clean and dry.

3.2 Foreign objects in engine


To prevent the ingress of foreign bodies during work on the
engine, seal all openings.
Seal openings with suitable bungs from engine bung set -VAS
6122-.

Note

In the event of mechanical damage on turbocharger, observe ⇒


page 354 .

3.3 Contact corrosion


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

3. Repair instructions 7
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Please note:
♦ Use genuine parts which are tested and compatible with
aluminium.
♦ The use of Volkswagen parts is recommended.
♦ Damage resulting from contact corrosion is not covered by
the warranty.

3.4 Routing and attachment of lines


Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Ensure there is sufficient clearance to moving or hot compo‐
nents.
– Cable ties, heat insulation sleeves, clips and similar that had
to be taken off for removal should be renewed if necessary.
Install them in the same position.

3.5 Fitting radiator and condensers


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

8 Rep. gr.00 - Technical data


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

10 – Removing and installing engine


1 Removing and installing engine
⇒ e1.1 ngine”, page 9
⇒ e1.2 ngine and gearbox”, page 21
⇒ e1.3 ngine on engine and gearbox support”, page 24
⇒ e1.4 ngine”, page 25

1.1 Removing engine

Caution

When installing a new base engine, it is compulsory to fix


and tighten the clamping pieces of the injectors to the speci‐
fied torque after installing the high-pressure lines ⇒ page
417 . Clamping jaws are only secured »hand-tight« for set‐
ting the injectors while installing high-pressure lines. Non-ob‐
servance of these notes may lead to damage to engine.

Special tools and workshop equipment required


♦ Engine and gearbox jack -VAS 6931-

♦ Engine bung set -VAS 6122-

1. Removing and installing engine 9


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Drip tray for workshop hoist -VAS 6208-

♦ Spring-type clip pliers -VAS 6362-

♦ Locking pin -T10060 A-

♦ Engine support -T10497- with pin -T10497/1-

♦ Engine support -T10497/4-

10 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Release lever -80 - 200-

♦ Protective mat -VAS 531003-


♦ Commercially available stepladder
♦ Safety glasses
♦ Safety gloves
Procedure

Note

♦ The engine is removed downwards together with the gear‐


box.
♦ Attach cable ties in all the same places when installing.
♦ Fit heat shield sleeves in the same place when installing.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;


Disconnecting and connecting battery.
– Remove engine cover panel ⇒ page 61 .
– Remove air filter and air duct ⇒ page 443 .
– Remove control unit for NOx sender -GX30- and place it on
engine together with line ⇒ page 471 .
– Remove air filter carrier ⇒ page 444 .

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
carefully to release pressure.

– Open filler cap -5- on coolant expansion tank.

1. Removing and installing engine 11


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Close filler cap -5- on coolant expansion tank.


– Release and pull off connector -2- on coolant expansion
tank.
– Unclip, release and pull off connector -4-.
– Unclip retainer for fuel lines on coolant expansion tank
-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Open plug-in connectors -A- and -B- for fuel lines and pull
off fuel lines. Separate plug-in connectors ⇒ Fuel supply -
diesel engines; Rep. gr. 20; Plug-in connectors; Disconnect‐
ing plug-in connectors.

– Unclip supply line -2- from toothed belt guard.

– Release electrical connector, and pull it off injector for reduc‐


ing agent -N474- -3-.
– Lay wiring harness to one side.
– Release and pull off supply line -2- ⇒ page 580 .

12 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clip -5-, and pull off intake hose.
– Release catch -arrow- and disconnect vacuum hose -1-.

1. Removing and installing engine 13


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

For the work steps below use removal lever -80 - 200- to unclip
the binding clips.

– Release and pull off connectors on plenum chamber bulk‐


head ⇒ page 396 .
– Free off electrical wire.
– Release and pull off connector -2- at solenoid valve -1-.

– Unscrew nuts -arrows-.


– Place solenoid valve -1- on engine together with vacuum
lines.
– Separate connector -2- on engine control unit -J623- ⇒ page
480 .

– Remove electrical connectors -3- and -4- from retainer, re‐


lease them, and pull them off.
– Move electrical lines free.

14 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release catches -arrows- and detach cover -1- for electron‐


ics box in engine compartment.

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


-1- for electronics box in engine compartment upwards.

– Remove nut -arrow-, detach electrical wiring and move clear.

– Remove radiator cowl ⇒ page 333 .


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

1. Removing and installing engine 15


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release rotary fastener of connector -1- by turning it towards


starter -A-.

– Pull off connector.


– Disconnect electrical connector -4-.

– Press off cap -5-.


– Unscrew nut -6- and remove terminal 30/B+.
– Unbolt earth wire from body.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.

16 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove selector mechanism from gearbox ⇒ Rep. gr. 34;


Selector mechanism; Removing and installing selector
mechanism.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44; Wheels, tyres; Specified torque for wheel bolts.
– Remove left and right front wheel housing liners ⇒ General
body repairs, exterior; Rep. gr. 66; Wheel housing liner; As‐
sembly overview - front wheel housing liner.
– Remove pendulum support ⇒ page 39 .
– Remove front exhaust pipe ⇒ page 501 .
– Remove subframe together with steering rack ⇒ Running
gear, axles, steering; Rep. gr. 40; Subframe; Removing and
installing subframe with steering rack.
– Remove heat shield for right drive shaft ⇒ Running gear,
axles, steering; Rep. gr. 40; Drive shaft; Removing and in‐
stalling drive shaft heat shield.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
– Remove left drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
– Remove propshaft ⇒ Propshaft and rear final drive; Rep.
gr. 39; Propshaft.
– Remove bracket for bevel box ⇒ Rep. gr. 34; Bevel box.
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Drain coolant ⇒ page 213 .
– Remove actuator for engine temperature regulation -N493-
with bracket ⇒ page 287 .
– Remove poly V-belt ⇒ page 67 .
– Remove air conditioner compressor with refrigerant lines
connected from engine ⇒ Heating, air conditioning; Rep.
gr. 87; Air conditioner compressor; Removing air conditioner
compressor from and installing to bracket.
– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side.
– Remove charge air cooling pump -V188- together with
bracket from engine ⇒ page 274 .
– Remove auxiliary pump for heating -V488- together with
bracket from engine ⇒ page 276 .
– Lift retaining clip -arrow- and disconnect coolant hose (top
left) from radiator.

1. Removing and installing engine 17


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Lift retaining clip -arrow- and disconnect coolant hose (top


right) from water radiator for charge air cooling circuit.

– Release retaining clips -arrows-, and pull the two plug-in


connectors -2- off water pipes -1-.

– Open clip -3-, and pull off water hose.


– If fitted, pull off coolant hoses -4- from auxiliary radiator -1-.

– To do this, release retaining clips -arrow-.


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

18 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows- for gearbox mounting approx. 2


turns.

– Release fasteners -arrows- and detach noise insulation -1-


for sump.

– Bolt engine support -T10497- with pin -T10497/1- to cylinder


block.

1. Removing and installing engine 19


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Using bolt -1-, bolt engine support -T10497- to cylinder block


to approx. 20 Nm.
– Fit adapter -T10497/4- to engine support -T10497- and tight‐
en bolt -1- to 20 Nm.

– Insert engine and gearbox jack -VAS 6931- into engine sup‐
port -T10497- and raise engine/gearbox assembly slightly.
– To unscrew bolts for assembly mounting use a commercially
available stepladder.

– Remove bolts -arrows- for engine mounting.


– Remove bolts -arrows- securing gearbox mounting.

20 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Danger of damage to vacuum lines or electrical wiring and to


engine compartment.
♦ Check that all vacuum lines and electrical wiring be‐
tween engine, gearbox and body have been detached.
♦ When lowering, carefully guide engine/gearbox assem‐
bly out of engine compartment.

– Lower engine/gearbox assembly.

1.2 Separating engine and gearbox


Special tools and workshop equipment required
♦ Lifting tackle -2024 A-

♦ Lifting eye bolt -3368-

1. Removing and installing engine 21


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Puller for ATF supply -T40123 A-

♦ Workshop hoist -VAS 6100-

Procedure

Note

The flywheel is equipped with centrifugal weights. The centrifu‐


gal weights generate a »clacking sound« when the engine is
cranked by hand. The »clacking sound« is generated by design
and there is no need to raise a complaint. When the cranking
speed is attained, the noise will disappear.

• Engine/gearbox assembly removed and attached to engine


bracket -T10497-.
– Remove air pipe ⇒ page 382 .
– Remove left coolant pipe ⇒ page 308 .
– Remove starter ⇒ Electrical system; Rep. gr. 27; Starter;
Removing and installing starter.
– Move wiring harnesses -arrows- on bracket clear to one
side.

22 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew eye on puller for ATF supply -T40123 A-, and


screw it to stop into lower threaded hole for starter bolt.

– Secure eye-head bolt -3368- with 2 counter-locked nuts -1-


in hole in gearbox housing.
– Attach lifting tackle -2024 A- to both eyes and to workshop
hoist -VAS 6100- as shown in illustration.

Note

In order to match the lifting tackle to the centre of gravity of the


gearbox, the holes in the hook rail must be allocated as shown
in the illustration.

WARNING

Risk of accidents due to loose components of the lifting tack‐


le.
♦ The support hooks and pins on the lifting tackle must be
secured with locking pins -arrows-.

– Unscrew bolts -1 to 8- securing gearbox to engine.

– Pull gearbox with bevel box off engine.

1. Removing and installing engine 23


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.3 Securing engine on engine and gear‐


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

Special tools and workshop


equipment required

♦ Lifting tackle -3033-


♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Workshop hoist -VAS 6100-
♦ Engine and gearbox support -VAS 6095-
Procedure
– Separate gearbox from engine ⇒ page 21 .
– Remove intermediate plate ⇒ page 83 .
– Attach lifting tackle -3033- as follows.

24 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Lift engine out of engine support -VAS 6100- using work‐


shop hoist -T10497-.
Flywheel end: position 3.
Vibration damper end: position 9.
– Secure engine on engine and gearbox support -VAS 6095/1-
using universal mounting -VAS 6095-.

1.4 Installing engine

Caution

When installing a new base engine, it is compulsory to fix


and tighten the clamping pieces of the injectors to the speci‐
fied torque after installing the high-pressure lines ⇒ page
417 . Clamping jaws are only secured »hand-tight« for set‐
ting the injectors while installing high-pressure lines. Non-ob‐
servance of these notes may lead to damage to engine.

Note

♦ After new components have been installed (engine/short en‐


gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

Specified torques
Component Nm
Bolts and nuts M6 10

1. Removing and installing engine 25


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Component Nm
M7 15
M8 20
M10 40
M12 65
♦ ⇒ o2.1 verview - assembly mountings”, page 29 .
♦ ⇒ Rep. gr. 34; Removing and installing gearbox; Installing
gearbox
Procedure

Note

The flywheel is equipped with centrifugal weights. The centrifu‐


gal weights generate a »clacking sound« when the engine is
cranked by hand. The »clacking sound« is generated by design
and there is no need to raise a complaint. When the cranking
speed is attained, the noise will disappear.

Note

♦ Renew bolts that are tightened with turning further angle


after each removal.
♦ Renew self-locking nuts and bolts as well as gaskets, seals
and O-rings after each removal.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ Attach cable ties in all the same places when installing.

– Install intermediate plate ⇒ page 83 .


– Install intermediate plate ⇒ page 82 .
– If there are no dowel sleeves -A- in the cylinder block for
centring the engine and gearbox, insert new dowel sleeves.

Note

The illustration shows a vehicle with manual gearbox.

26 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If no needle bearing is fitted in crankshaft, install needle


bearing ⇒ page 97 .
– Install intermediate plate ⇒ page 83 .
– Bolt gearbox to engine ⇒ page 21 .
– Take up engine/gearbox assembly with engine support -
T10497-.
– Make sure the wires of the exhaust gas temperature senders
are properly routed ⇒ page 584 .
– Guide engine/gearbox assembly into body.
– First screw bolts -arrows- for engine mountings into stop by
hand.

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


hand.

Note

The bolts are tightened to final torque only after adjusting the
assembly mountings ⇒ page 57 .

– Remove engine support -T10497- from engine.


– Install starter ⇒ Electrical system; Rep. gr. 27; Starter; As‐
sembly overview - starter.
– Install actuator for engine temperature regulation -N493- ⇒
page 287 .
– Install charge air cooling pump -V188- ⇒ page 271 .
– Install auxiliary pump for heating -V488- ⇒ page 271 .
– Install bracket for bevel box ⇒ Rep. gr. 34; Bevel box.

1. Removing and installing engine 27


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Install drive shafts ⇒ Running gear, axles, steering; Rep.


gr. 40; Drive shaft; Assembly overview - drive shaft.
– Install heat shield for drive shaft ⇒ Running gear, axles,
steering; Rep. gr. 40; Drive shaft; Removing and installing
drive shaft heat shield.
– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
– Install poly V-belt ⇒ page 67 .
– Install engine control unit ⇒ page 480 .
– Install cables with cable support bracket ⇒ Rep. gr. 34; Se‐
lector mechanism; Assembly overview - selector cables.
– Install propshaft ⇒ Propshaft and rear final drive; Rep.
gr. 39; Propshaft.
– Install front exhaust pipe ⇒ page 501 .
– Install radiator cowl ⇒ page 333 .
– Install subframe ⇒ Running gear, axles, steering; Rep.
gr. 40; Subframe; Removing and installing subframe with
steering rack.
Install pendulum support ⇒ page 39 .
– Install front wheel housing liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Wheel housing liner; Assembly overview -
front wheel housing liner.
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
– Install front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44; Wheels, tyres; Specified torque for wheel bolts.
– Adjust assembly mountings ⇒ page 57 .
– Install carrier for air filter and intake hose ⇒ page 441 .
– ⇒ Electrical system; Rep. gr. 27; Battery; Exploded view -
battery
– Route wires ⇒ Electrical system; Rep. gr. 97; Relay carriers,
fuse carriers, electronics boxes; Overview of fitting locations
- relay carriers, fuse carriers, electronics boxes and ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting loca‐
tions.
– Connect vacuum hoses ⇒ page 412 .
– Check oil level ⇒ Maintenance; Booklet .
– Connect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and connecting battery.
– Bleed fuel system ⇒ page 410 .
– Connect coolant hoses with plug-in connector to heat ex‐
changer for heater ⇒ page 324 .
– Add coolant ⇒ page 215 .

Note

Never reuse old coolant.

28 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Assembly mountings
⇒ o2.1 verview - assembly mountings”, page 29
⇒ a2.2 nd installing engine mounting”, page 33
⇒ a2.3 nd installing gearbox mounting”, page 35
⇒ a2.4 nd installing pendulum support”, page 39
⇒ e2.5 ngine in installation position”, page 40
⇒ a2.6 ssembly mountings”, page 57
⇒ a2.7 djustment of assembly mountings”, page 60

2.1 Assembly overview - assembly mount‐


ings
⇒ o2.1.1 verview - assembly mountings, Passat and Arteon”,
page 29
⇒ o2.1.2 verview – assembly mountings, Tiguan”, page 31

2.1.1 Assembly overview - assembly mountings, Passat and Arteon

2. Assembly mountings 29
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bolt
❑ Renew after removal
❑ Tightening sequence ⇒
page 73
2 - Engine support
❑ Removing and instal‐
ling ⇒ page 72
3 - Engine mounting
❑ With support arm
❑ Removing and instal‐
ling ⇒ page 33
4 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
5 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
6 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
7 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
8 - Pendulum support
❑ Removing and instal‐
ling ⇒ page 39
❑ Tightening sequence
and specified torque: ⇒
page 31
9 - Bolt
Volkswagen Technical Site: https://vwts.ru
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 31
10 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 31
11 - Bolts
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 31
12 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
13 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
14 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ page 35
15 - Bolt

30 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Renew after removal
❑ 50 Nm +90°
16 - Bolt
❑ Specified torque: ⇒ Rep. gr. 34; Assembly mountings; Assembly overview - assembly mountings
17 - Rear final drive support
❑ For vehicles with manual gearbox
18 - Bolt
❑ Specified torque: ⇒ Rep. gr. 34; Assembly mountings; Assembly overview - assembly mountings

Bolted connection for pendulum support

Note

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

– Tighten bolts in stages in the sequence shown.


Specified torques
Stage Bolts Specified torque/turning further angle
1 -2, 3- 50 Nm
2 -1- 130 Nm
3 -1 to 3- Turn 90° further

2.1.2 Assembly overview – assembly mountings, Tiguan

2. Assembly mountings 31
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Engine support
❑ Removing and instal‐
ling ⇒ page 72
2 - Bolt
❑ Renew after removal
❑ Specified torque and
tightening sequence,
bolt allocation ⇒ page
73
3 - Engine mounting
❑ With support arm
❑ Removing and instal‐
ling ⇒ page 33
4 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
5 - Centre hex stud
❑ Renew after removal
❑ 40 Nm +90°
6 - Bolt
❑ Renew after removal
❑ 40 Nm +90°
7 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
8 - Pendulum support
❑ Removing and instal‐
ling ⇒ page 39
❑ Tightening sequence
and specified torque: ⇒
page 33
9 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 33
10 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 33
11 - Bolts
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 33
12 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
13 - Centre hex stud
❑ Renew after removal
❑ 50 Nm +90°
14 - Gearbox mounting
❑ With support arm

32 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Removing and installing ⇒ page 35
15 - Bolt
❑ Renew after removal
❑ 50 Nm +90°

Bolted connection for pendulum support

Note

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

– Tighten bolts in stages in the sequence shown.


Specified torques
Stage Bolts Specified torque/turning further angle
1 -2, 3- 50 Nm
2 -1- 130 Nm
3 -1 to 3- Turn 90° further

2.2 Removing and installing engine mount‐


ing
Removing
– Remove engine cover panel ⇒ page 61 .
– Release and pull off connector -2- on coolant expansion
tank.

– Unclip connector -4-.

2. Assembly mountings 33
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip retainer for fuel lines on coolant expansion tank


-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Open plug-in connectors -A- and -B- for fuel lines and pull
off fuel lines. Disconnect plug-in connectors ⇒ Rep. gr. 20;
Plug-in connectors; Disconnecting plug-in connectors.

– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.
– Support engine and gearbox in installation position ⇒ page
40 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -arrows- and remove engine mounting -1-.

Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ page 60 .
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ Rep. gr. 20; Fuel filter; Assembly overview - fuel filter
♦ ⇒ Electrical system; Rep. gr. 92; Windscreen wiper system;
Assembly overview – windscreen wiper system

34 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.3 Removing and installing gearbox


mounting
⇒ a2.3.1 nd installing gearbox mounting, Passat and Arteon”,
page 35
⇒ a2.3.2 nd installing gearbox mountings, Tiguan”, page 37

2.3.1 Removing and installing gearbox


mounting, Passat and Arteon
Removing
– Remove air filter and air duct ⇒ page 443 .
– Remove control unit for NOx sender -GX30- on air filter car‐
rier and place it on engine together with line ⇒ page 471 .
– Remove air filter carrier ⇒ page 444 .
– Remove engine control unit -J623- from bracket ⇒ page
480 .
– Unscrew nuts -arrows- and remove bracket -1-.

Note

Different types of brackets are fitted depending on version.

– Unclip battery positive wire from cable guide.

2. Assembly mountings 35
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip cover of cable guide.


– Lay wiring harness to one side. To do this, detach cable ties.
– Unclip cable guide from longitudinal member -arrows-, and
guide it out.
– Unscrew nuts -arrows-.

– Remove retainer -1- from water pipe -4- and gearbox mount‐
ing -3-.
– Support engine and gearbox in installation position ⇒ page
40 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Remove bolts -arrows- and detach gearbox mounting -1-.

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

Note

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

– Tighten gearbox mounting on longitudinal member.

36 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Risk of damaging thread in gearbox support if bolts are star‐


ted at an angle.
♦ Gearbox support and support arm of gearbox mounting
must be perfectly parallel to each other before screwing
in bolts. If necessary, lift gearbox at rear using trolley
jack.
♦ Do not remove support bracket -10 - 222 A- until the
bolts securing the assembly mounting have been tight‐
ened to specified torque.

– Lift gearbox with spindle of support bracket until gearbox


support makes contact with support arm of gearbox mount‐
ing.
– Checking adjustment of assembly mountings ⇒ page 60 .
– Remove support bracket -10 - 222 A- from engine.
Specified torque
Bolts Specified torque
Bracket between wa‐ 20 Nm
ter pipe and gearbox
mounting
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ a7.1 nd installing engine control unitJ623”, page 480
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ Electrical system; Rep. gr. 92; Windscreen wiper system;
Assembly overview – windscreen wiper system

2.3.2 Removing and installing gearbox


mountings, Tiguan
Removing
– Remove air filter housing and air duct ⇒ page 443 .
– Remove control unit for NOx sender -GX30- on air filter car‐
rier and place it on engine together with line ⇒ page 471 .
– Remove air filter carrier ⇒ page 444 .
– Unscrew nuts -arrows B-.

– Remove bracket -1- from gearbox mounting -3-.

2. Assembly mountings 37
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off coolant lines -4- from bracket -arrow A-.
– Lay coolant lines to side.
– Support engine and gearbox in installation position ⇒ page
40 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -2-, then unscrew bolts -arrows-.

– Remove gearbox mounting -1-.


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

Note

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

– Tighten gearbox mounting on longitudinal member.

Caution

Risk of damaging thread in gearbox support if bolts are star‐


ted at an angle.
♦ Gearbox support and support arm of gearbox mounting
must be perfectly parallel to each other before screwing
in bolts. If necessary, lift gearbox at rear using trolley
jack.
♦ Do not remove support bracket -10 - 222 A- until the
bolts securing the assembly mounting have been tight‐
ened to specified torque.

– Lift gearbox with spindle of support bracket until gearbox


support makes contact with support arm of gearbox mount‐
ing.
– Checking adjustment of assembly mountings ⇒ page 60 .
– Remove support bracket -10 - 222 A- from engine.
Specified torque
Bolts Specified torque
Retainer for coolant 20 Nm
lines on gearbox
mounting

38 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ o2.1 verview - assembly mountings”, page 29


♦ ⇒ o4.1 verview - air filter housing”, page 441

2.4 Removing and installing pendulum


support
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Unscrew bolts -1- to -3-, and remove pendulum support.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

There are threaded inserts, e.g. “Heli-Coil” in the bolting holes


for the pendulum support.

Identification: shoulder along beginning of thread -arrow-.

Bolted connection for pendulum support

2. Assembly mountings 39
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

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

– Tighten bolts in stages in the sequence shown ⇒ page 39 .


Specified torques
♦ ⇒ page 39
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.5 Supporting engine in installation posi‐


tion
⇒ e2.5.1 ngine in installation position, Passat”, page 40
⇒ e2.5.2 ngine in installation position, Tiguan”, page 45
⇒ e2.5.3 ngine in installation position, Arteon”, page 51

2.5.1 Supporting engine in installation posi‐


tion, Passat
Special tools and workshop equipment required
♦ Support bracket -10 - 222 A-

40 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Adapter -10-222A/1-

♦ Square section tube -T40091/1-, qty. 2

♦ Joints -T40091/3-

♦ Support -T40093/3-
♦ Adapter -T40093/3-6A-

2. Assembly mountings 41
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Spindle -10 - 222 A /10-

♦ Shackle -10 - 222 A /12-

– Remove engine cover panel ⇒ page 61 .


– Press release tabs on crankcase breather hose -4-, and
remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5- and pull off intake hose.
– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.
– If there are hose and cable connections in area of engine
support eyes for support bracket -10 - 222 A-, remove these
now.
– Connect adapter-T40093/3-6A- to support -T40093/3-.
– If fitted, pull off electrical wiring in front area of web on longi‐
tudinal member. Do not disconnect pipe/hose system.
– Place adapter-T40093/3-6A- on right longitudinal member. If
necessary, unclip refrigerant line from retainer.

42 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

• The adapter-T40093/3-6A- is locked with the pin -A- behind


the flange of the longitudinal member -arrow-.
– If necessary, push adapter -T40093/3-6A- into correct posi‐
tion.
– Remove foam elements -arrows- for plenum chamber seal
on left and right.

– Bolt adapter -10-222A/1- -A- to right of support bracket


-10-222 A- -B-.

– Push one connecting piece -T40091/3- -D- onto square tube


of support bracket -10-222 A-.
– Bolt adapter -10-222A/1- to left of support bracket -10-222
A-.

2. Assembly mountings 43
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Fit support bracket onto longitudinal members.


– On both sides of vehicle, fit adapter -10 - 222 A /1- -A- to‐
gether with support bracket -10-222 A- -B- onto longitudinal
member -arrow- as shown in illustration.
Support engine in installation position:

A - Adapter -10-222A/1-
B - Square tube of support
bracket -10-222 A-
C - Square tube -T40091/1-
D - Connector -T40091/3-
E - Adapter -T40093/3-
F - Spindle -10 - 222 A /10-
G - Shackle -10 - 222 A /12-

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


T40093/3- on right side.
– Push both spindles onto square tube -T40091/1- as shown.
– Push square tube -T40091/1- into connecting piece -
T40091/3-.
– Attach spindle -10 - 222 A /10- with shackle -10 - 222 A /12-
to left lifting eye.
– Connect right support eye of engine to spindle using a
shackle -10 - 222 A /12-.
– Align support bracket.
– Tighten all threaded connections of support bracket.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.

44 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.5.2 Supporting engine in installation position, Tiguan

2. Assembly mountings 45
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Special tools and workshop


equipment required

46 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Support bracket -10 - 222 A-


♦ Hook -10-222A/10-
♦ Adapter -10-222A/28-
♦ Adapter -10-222A/28-2-
♦ 2 x adapter -10 - 222 A /29-
♦ 2 × -T40091/1- and -T40091/3- from engine support basic
set -T40091-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10-222A/28-
Procedure

Note

The securing bolts for the assembly mountings must be re‐


moved only if the engine is supported in installation position
using the support bracket -10-222 A-!

– Remove engine cover panel ⇒ page 61 .


– Press release tabs on crankcase breather hose -4-, and
remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5- and pull off intake hose.
– Open retainer -arrow- and unclip fuel lines -1-.

– Unclip retainer.
– Remove foam elements -arrows- for plenum chamber seal
on left and right.

2. Assembly mountings 47
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows- for retaining brackets on left and


right of lock carrier.

– Unscrew lower mounting from adapter -10 - 222 A /28-.

– Screw in adapter -10-222 A /28-2-.


– Unscrew bolts -arrows- for securing support bracket to lock
carrier from adapter -10-222 A /28-2-.
– Bolt adapter -10-222 A /28-2- to lock carrier using securing
bolt -1-.

48 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ Use bolts from adapters -10-222 A /28-2- to secure adapters


-10 - 222 A /28-. Do not use retaining bracket securing bolts
for this purpose.
♦ The adapters -10-222 A /28-2- can also be secured at the
front bolting point.

• Specified torque for bolts -1-: 8 Nm

Caution

A second mechanic is required to place the support bracket


on the vehicle in order to prevent the support bracket from
tipping.

Installation position of adapters -10 - 222 A /29-:


♦ “L” = -1- adapter is used on “right-hand” side of vehicle.
♦ “R” adapter is inserted on “left” side of vehicle.
♦ On both sides of vehicle, insert adapters -10 - 222 A /29-
between upper wheel housing longitudinal members and
mounting plate for wing located underneath.
Setting up support bracket:
– Bolt adapter -10 - 222 A /29- labelled »L« to right side of
support bracket -10-222 A-.
– Push one connecting piece -T40091/3- onto square tube -10
- 222 A-.
– Securing bolts for connecting piece -T40091/3- point in di‐
rection of vehicle travel, as indicated in illustration.
– Push spindle -10-222A- onto square tube -10 - 222 A-.
– When pushing on the spindle, make sure that the threaded
rod is seated in front of the square tube (as seen from the
driver’s perspective).
– Push second connecting piece -T40091/3- onto square tube
-10 - 222 A-.
– Securing bolts for connecting piece -T40091/3- point in di‐
rection of vehicle travel, as indicated in illustration.
– Bolt adapter -10 - 222 A /29- labelled »R« to left side of sup‐
port bracket -10-222 A-.
– Fit support bracket -10 - 222 A- onto longitudinal members.

2. Assembly mountings 49
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Fit support bracket -10 - 222 A- behind bonnet support -1-,


as shown in illustration.

– Align support bracket -10 - 222 A- on longitudinal member


so that spindle -10-222A- is located directly above the eye
on the left side.
– Push square tube -T40091/1- on right side into adapter -10 -
222 A /28-.
– Push spindle -10-222A- on right side onto square tube -
T40091/1-.
– Push square tube -T40091/1- on right side into connecting
piece -T40091/3-.
– Push square tube -T40091/1- on left side into adapter -10 -
222 A /28-.
– Push square tube -T40091/1- on left side into connecting
piece -T40091/3-.
– Screw shackles -10 - 222 A /12- onto support eyes on left
and right sides.
– Hookspindle -10-222A- onto shackle -10 - 222 A /12- on
right side.

– Attach spindle -10-222A- to shackle -10 - 222 A /12- on left


side.
– Align support bracket.
– Tighten all threaded connections of support bracket.

50 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Tighten spindle slightly to take up weight of engine/gearbox


assembly; do not lift.

2.5.3 Supporting engine in installation posi‐


tion, Arteon
Special tools and workshop equipment required
♦ Support bracket -10 - 222 A-

♦ Square section tube -T40091/1-, qty. 2

♦ Connecting piece -T40091/3-, qty. 2


♦ Support -T40093/3-

2. Assembly mountings 51
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Adapter -T40093/3-6A-

♦ Spindle -10 - 222 A /10-

♦ Shackle -10 - 222 A /12-

♦ Adapter -10-222A/8-

52 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

The securing bolts for the assembly mountings must be re‐


moved only if the engine is supported in installation position
using the support bracket -10-222 A-!

– Remove engine cover panel ⇒ page 61 .


– Press release tabs on crankcase breather hose -4-, and
remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5- and pull off intake hose.
– Detach fuel filter, and place it on engine with lines still at‐
tached ⇒ Fuel supply - diesel engines; Rep. gr. 20; Fuel
filter; Removing and installing fuel filter.
– Connect adapter-T40093/3-6A- to support -T40093/3-.
– If fitted, pull off electrical wiring in front area of web on longi‐
tudinal member. Do not disconnect pipe/hose system.
– Place adapter-T40093/3-6A- on right longitudinal member. If
necessary, unclip refrigerant line from retainer.

• The adapter-T40093/3-6A- is locked with the pin -A- behind


the flange of the longitudinal member -arrow-.

2. Assembly mountings 53
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Fit adapter-T40093/3-6A- -A- to left longitudinal member.

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


longitudinal member. Do not disconnect pipe/hose system.
– Place adapter -T40093/3-6A- onto left longitudinal member.
– The adapter -T40093/3-6A- locks with pin -A- behind web of
longitudinal member -arrow-.
– If necessary, push adapter -T40093/3-6A- into correct posi‐
tion.
– Remove foam elements -arrows- for plenum chamber seal
on left and right.

– Bolt adapter -10-222A/8- -A- to right of support bracket


-10-222 A- -B-.

54 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Push one connecting piece -T40091/3- -D- onto square tube


of support bracket -10-222 A-.
– Push spindle -10 - 222 A /10- -F- onto square tube of sup‐
port bracket -10-222 A-. When doing this, make sure that
threaded spindle points towards rear in direction of wind‐
screen.
– Push another connecting piece -T40091/3- -D- onto square
tube of support bracket -10-222 A-.
– Bolt adapter -10-222A/8- to left of support bracket -10-222
A-.
– Fit support bracket onto longitudinal members.
– On both sides of vehicle, fit adapter -10 - 222 A /8- -A- to‐
gether with support bracket -10-222 A- -B- onto longitudinal
member behind bolt -arrow- as shown in illustration.

Support engine in installation position:

2. Assembly mountings 55
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

A - Adapter -10-222A/8-
B - Square tube of support
bracket -10-222 A-
C - Square tube -T40091/1-
D - Connector -T40091/3-
E - Adapter -T40093/3-
F - Spindle -10 - 222 A /10-
G - Shackle -10 - 222 A /12-

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


T40093/3- and connecting piece -T40091/3- on left side.
– Push square section tube -T40091/1- into adapter -
T40093/3- on right side.
– Push spindle onto square section tube -T40091/1- on right
side, as shown in illustration.
– Push square section tube -T40091/1- into right connecting
piece -T40091/3-.
– Attach spindle -10 - 222 A /10- with shackle -10 - 222 A /12-
to left lifting eye.
– Connect right support eye of engine to spindle using a
shackle -10 - 222 A /12-.
– Align support bracket.
– Tighten all threaded connections of support bracket.
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.

56 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.6 Adjusting assembly mountings


⇒ a2.6.1 ssembly mountings, Passat and Arteon”, page 57
⇒ a2.6.2 ssembly mountings, Tiguan”, page 58

2.6.1 Adjusting assembly mountings, Passat


and Arteon
Procedure
– Support engine and gearbox in installation position ⇒ page
40 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew engine mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐
gine).

– First screw bolts in loosely.


– Unscrew gearbox mounting bolts -arrows- one after the oth‐
er and renew them (if not already renewed when installing
engine).
– Unscrew bolts -arrows- for gearbox mounting approx. 2
turns.

– First screw bolts in loosely.


– Using assembly lever, adjust engine/gearbox assembly until
specifications listed below are attained:

2. Assembly mountings 57
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

• There must be a distance of -a- = 10 mm between engine


support -2- and engine mounting -1-.
• Side surface of the engine support casting should be located
parallel to support arm of engine mounting.
• Distance -b- = distance -b-.

Note

Check distance -a- = 10 mm using, for example, a suitable rod.

– Tighten bolts for engine mounting.


– On gearbox side, ensure that support arm and gearbox
mounting are parallel.

• Distance -x- = distance -x-.


– Tighten bolts for gearbox mounting.
Install in reverse order of removal.
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ Electrical system; Rep. gr. 92; Windscreen wiper system;
Assembly overview – windscreen wiper system

2.6.2 Adjusting assembly mountings, Tiguan


Procedure
– Support engine and gearbox in installation position ⇒ page
40 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.

58 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew engine mounting bolts -arrows- one after the other


and renew them (if not already renewed when installing en‐
gine).

– First screw bolts in loosely.


– Unscrew gearbox mounting bolts -arrows- one after the oth‐
er and renew them (if not already renewed when installing
engine).
– Unscrew bolts -arrows- for gearbox mounting approx. 2
turns.

– First screw bolts in loosely.


– Using assembly lever, adjust engine/gearbox assembly until
specifications listed below are attained:

• There must be a distance of -a- = 10 mm between engine


support -2- and engine mounting -1-.
• Side surface of the engine support casting should be located
parallel to support arm of engine mounting.
• Distance -b- = distance -b-.

2. Assembly mountings 59
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

Check distance -a- = 10 mm using, for example, a suitable rod.

– Tighten bolts for engine mounting.


– On gearbox side, ensure that support arm and gearbox
mounting are parallel. Dimension -a-.

– Tighten bolts for gearbox mounting.


Install in reverse order of removal.
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 29

2.7 Checking adjustment of assembly


mountings
Procedure
The following specifications must be obtained:

• There must be a distance of -a- = 10 mm between engine


support -2- and engine mounting -1-.
• Side surface of engine support casting should be located
parallel to support arm of engine mounting.

Note

Check distance -a- = 10 mm using, for example, a suitable rod.

– If the dimension is too small or too high, adjust assembly


mountings ⇒ page 57 .

60 Rep. gr.10 - Removing and installing engine


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Engine cover panel


⇒ a3.1 nd installing engine cover”, page 61

3.1 Removing and installing engine cover


Removing

Caution

Make sure not to accidentally touch or pull on the fuel return


line when removing and installing the engine cover panel.
Otherwise the connections on the injectors may break, and
leaks in the fuel system may result.

– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not pull off engine cover panel abrupt‐
ly or only on one side.
Installing
– Make sure that insulation -1- is properly seated on lines -2-
and on engine.

– To prevent damage, do not strike engine cover panel with


your fist or a tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into rubber grommets first on the
left side and then on the right side as seen facing direction of
travel.

3. Engine cover panel 61


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ o1.1 verview - cylinder block (pulley end)”, page 62
⇒ o1.2 verview - sealing flange, belt pulley end”, page 65
⇒ a1.3 nd installing poly-V belt”, page 67
⇒ a1.4 nd installing tensioner for poly V-belt”, page 68
⇒ a1.5 nd installing vibration damper”, page 69
⇒ a1.6 nd installing bracket for ancillaries”, page 70
⇒ a1.7 nd installing engine support”, page 72
⇒ a1.8 nd installing sealing flange on pulley end”, page 74
⇒ c1.9 aps in cylinder block (pulley end)”, page 77

1.1 Assembly overview - cylinder block (pulley end)

62 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Spacer sleeve
❑ Observe notes ⇒ page
64
❑ 4 Nm
2 - Bolt
❑ Use only genuine bolts
⇒ Electronic parts cata‐
logue.
❑ Renew after removal
❑ 23 Nm
3 - High-pressure pump
❑ Assembly overview ⇒
page 488
❑ Removing and instal‐
ling ⇒ page 490
4 - Bolt
❑ Qty. 6
❑ Renew after removal
❑ Different lengths ⇒
page 64 .
❑ Specified torque and
tightening sequence: ⇒
page 64
5 - Ancillary bracket
❑ Removing and instal‐
ling ⇒ page 70
6 - Alternator
❑ Assembly overview
⇒ Electrical system;
Rep. gr. 27; Alternator;
Assembly overview - al‐
ternator
7 - Air conditioner compressor
❑ Assembly overview ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly
overview - drive unit of air conditioner compressor.
8 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view – drive unit of air conditioner compressor.
9 - Dowel sleeve
❑ Ensure correct seating in air conditioner compressor bracket
10 - Poly V-belt
❑ Check for wear
❑ Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ Do not kink
❑ Poly V-belt routing ⇒ page 67
❑ Removing and installing ⇒ page 67
❑ When installing, make sure it is properly seated on pulleys.
11 - Tensioning device for poly V-belt
❑ Removing and installing ⇒ page 68
12 - Bolt
❑ Renew after removal

1. Cylinder block (pulley end) 63


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ 20 Nm +90°
13 - Bolt
❑ Specified torque: ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview – alternator
14 - Vibration damper
❑ With poly V-belt pulley
❑ Installation position: hole in vibration damper must align over protrusion on crankshaft pulley.
❑ Removing and installing ⇒ page 69
15 - Bolt
❑ Use only genuine bolts ⇒ Electronic parts catalogue.
❑ Renew after removal
❑ M8 × 20: 10 Nm +90°
❑ M8 × 50: 20 Nm +180°
16 - Bolt
❑ Specified torque: ⇒ page 488
17 - Bolt
❑ Specified torque: ⇒ page 488
18 - Dowel sleeve
❑ Check for correct seating in ancillary bracket.
19 - Bolt
❑ Specified torque: ⇒ Item 14 (page 139)
20 - Idler roller

Ancillary bracket - specified torques and tightening sequence

64 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ There is a spacer sleeve fitted at item 7. The securing bolt is


screwed into the cylinder head through the sleeve ⇒ Item 1
(page 63) .
♦ Only if the entire base engine needs to be renewed, the
spacer sleeve must be unscrewed, and the threads in the
ancillary bracket must be cleaned with a thread chaser.
♦ Once the bolts of the ancillary bracket have been tightened,
a new spacer sleeve must be screwed on as far as stop at
the cylinder head and tightened to 4 Nm.
♦ Renew bolts that are tightened with turning further angle
after each removal.

– Install bolts as follows:


♦ Bolts -1, 2, 3, 4- M 10 × 35.
♦ Bolt -5- M10 × 175.
♦ Bolt -6- M10 × 115.
♦ Bolt -7- M8 × 60.
– Tighten bolts in stages in the sequence shown.
Sta Bolts Specified torque/turning further
ge angle
1 -1- to -7- Screw in by hand as far as stop
2 -1- to -6- 40 Nm
3 -7- 23 Nm
4 -5- and -6- Turn 180° further
5 -1- to -4- Turn 45° further

1.2 Assembly overview - sealing flange, belt pulley end

1. Cylinder block (pulley end) 65


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1 - Sealing flange at belt pul‐


ley end
❑ With crankshaft oil seal
❑ Renew after removal
❑ Removing and instal‐
ling ⇒ page 74
2 - Bolt
❑ Specified torque and
tightening sequence: ⇒
page 66
3 - Crankshaft pulley
❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in
one position
4 - Bolt
❑ Specified torque: ⇒
Item 1 (page 139)

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


ening sequence

– Tighten bolts in stages in the sequence shown.


Stage Bolts Specified torque
1 -1 to 6- Screw in by hand as far as stop
2 -1 to 6- In diagonal sequence to 13 Nm

66 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.3 Removing and installing poly-V belt


Special tools and workshop equipment required
♦ Locking pin -T10060 A-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.

– Before removing the poly V-belt, use a piece of chalk or a


felt pen to mark the running direction.
– To slacken poly V-belt turn tensioning device in anti-clock‐
wise direction -arrow- using ring spanner.
– Use the locking pin -T10060 A- to lock the tensioner.
– Remove poly V-belt.
Installing
Install in reverse order of removal, observing the following:
– Fit poly V-belt on poly V-belt pulley:

1. Cylinder block (pulley end) 67


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1- Vibration damper
2- Tensioning pulley
3- Alternator
4- Air conditioner compressor
– Hold tensioner with ring spanner and remove locking pin
-T10060 A-.

– Release tensioner.
– Check poly V-belts are in correct position.
– Start engine and check if belt runs properly.
Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

1.4 Removing and installing tensioner for


poly V-belt
Removing

– Remove poly V-belt ⇒ page 67 .


– Remove bolts -arrows- and take off poly V-belt tensioning
device.
Installing
Install in reverse order of removal, observing the following:
– Install poly V-belt ⇒ page 67 .

68 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

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

Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 62

1.5 Removing and installing vibration


damper

Note

The flywheel is equipped with centrifugal weights. The centrifu‐


gal weights generate a »clacking sound« when the engine is
cranked by hand. The »clacking sound« is generated by design
and there is no need to raise a complaint. When the cranking
speed is attained, the noise will disappear.

Removing

– Remove poly V-belt ⇒ page 67 .


– Loosen bolts for vibration damper. To do this, counterhold
on crankshaft pulley bolt with ring spanner.
– Unscrew bolts and remove vibration damper.
Installing
Install in reverse order of removal, observing the following:

• Installation position: hole -arrow- in vibration damper must


align over protrusion on crankshaft pulley.
– Install poly V-belt ⇒ page 67 .

1. Cylinder block (pulley end) 69


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

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

Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 62

1.6 Removing and installing bracket for an‐


cillaries
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove front sections of front right wheel housing liner
⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview - front wheel housing liner.
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Remove actuator for engine temperature regulation -N493-


with bracket and coolant hoses connected ⇒ page 287 .
– Tie up actuator for engine temperature regulation -N493- on
the side.
– Unbolt front right coolant pipe ⇒ page 303 .
– Remove air conditioner compressor with refrigerant lines
connected from engine ⇒ Heating, air conditioning; Rep.
gr. 87; Air conditioner compressor; Removing air conditioner
compressor from and installing to bracket.
– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side.
– Remove alternator ⇒ Electrical system; Rep. gr. 27; Alterna‐
tor; Removing and installing alternator.
– Remove high-pressure pump ⇒ page 490 .
– Unscrew bolt -arrow- and remove idler roller.

70 Rep. gr.13 - Crankshaft group


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– Loosen bolts in the sequence -7- to -1-.

– Unscrew bolts in the sequence -1- to -7-.


– Remove ancillary bracket.
Installing
Install in reverse order of removal, observing the following:
– Check that a dowel sleeve is fitted between bracket for ancil‐
laries and cylinder block.

1. Cylinder block (pulley end) 71


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Note

♦ There is a spacer sleeve fitted at item 7. The securing bolt is


screwed into the cylinder head through the sleeve ⇒ Item 1
(page 63) .
♦ Only if the entire base engine needs to be renewed, the
spacer sleeve must be unscrewed, and the threads in the
ancillary bracket must be cleaned with a thread chaser.
♦ Once the bolts of the ancillary bracket have been tightened,
a new spacer sleeve must be screwed on as far as stop at
the cylinder head and tightened to 4 Nm.

Specified torques
♦ ⇒ Fig. ““Ancillary bracket - specified torques and tightening
sequence”“, page 64
♦ ⇒ o2.2 verview - toothed belt”, page 138
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o8.1 verview - high-pressure pump”, page 488
♦ ⇒ Electrical system; Rep. gr. 27; Alternator; Exploded view -
alternator
♦ ⇒ Heating, air conditioning system; Rep. gr. 87; Air condi‐
tioning compressor; Removing and installing air conditioning
compressor from bracket

1.7 Removing and installing engine sup‐


port
Removing
– Removing engine mounting ⇒ page 33 .
– Remove upper part of toothed belt guard ⇒ page 140 .
– Remove lower toothed belt guard ⇒ page 144 .
– Using spindle -10 - 222 A /11-, raise or lower engine until
respective bolt of engine support becomes accessible.

72 Rep. gr.13 - Crankshaft group


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Note

To remove bolts -1- and -2-, the engine support must first be
removed.

– Unscrew bolts -1, 2 and 3-, and remove engine support.

Installing
Install in reverse order of removal, observing the following:
– Insert lower toothed belt guard and engine mounting togeth‐
er into engine, and position them.
– Fit bolts -1- and -2- into hole in engine support before insert‐
ing engine support.
– Tighten lower toothed belt guard ⇒ page 138 .
– Fit engine support, and tighten bolts -1- to -3- by hand.

– Then, tighten the bolts to specified torque and in correct


tightening sequence ⇒ page 73 .
– Install upper toothed belt guard ⇒ page 140 .
– Install engine mounting ⇒ page 33 .
Engine support - specified torque and tightening sequence, bolt
allocation

1. Cylinder block (pulley end) 73


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1 - Bolt M10 x 95
2 - Bolt M10 x 95
3 - Bolt M10 x 105

Note

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

– Tighten bolts in stages in the sequence shown.


Specified torques
Stage Bolts Specified torque/turning further angle
1 -1 to 3- 7 Nm
2 -1 to 3- 40 Nm
3 -1 to 3- Turn 180° further
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ o2.1 verview - assembly mountings”, page 29

1.8 Removing and installing sealing flange


on pulley end
Special tools and workshop equipment required
♦ Counterhold -3415-

74 Rep. gr.13 - Crankshaft group


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♦ Assembly tool -T10053-

♦ Hand drill with plastic brush


♦ Applicator gun -VAS 6966-

♦ Safety glasses
♦ Cleaning solution -D 291 091 A1-
♦ Sealant ⇒ Electronic Parts Catalogue
Removing
– Remove front right wheel housing liners ⇒ General body
repairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - front wheel housing liner.
– Remove toothed belt from camshaft ⇒ page 161 .
– Remove lower toothed belt guard ⇒ page 144 .
– Remove toothed belt from remaining toothed belt pulleys.
– Pull or push toothed belt as far upwards as possible to pre‐
vent it from being soiled or damaged.
– Using counterhold tool -3415-, loosen bolt -1- for crankshaft
pulley -2-.

1. Cylinder block (pulley end) 75


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– Remove bolt and detach crankshaft sprocket.


– Remove sump ⇒ page 186 .
– Unscrew bolts -1-.

– Carefully detach sealing flange -2- from adhesive bond, and


remove it.
Installing

Caution

Risk of eye injury caused by sealant residue.


♦ Wear safety goggles.

– Remove sealant residue from sealing surfaces on cylinder


block and sump using chemical sealant remover.
– Clean sealing surfaces with cleaning solution -D 291 091
A1-.

Note

The cleaning solution -D 291 091 A1- is used to activate the


surface before the sealant is applied and is essential for the
proper functionality of the sealing bond.

76 Rep. gr.13 - Crankshaft group


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– Position sleeve -T10053/1- on crankshaft journal.

Note

The oil seal sealing lip must not be additionally oiled or


greased.

– Push new sealing flange over sleeve -T10053/1-.


• Dowel pins should then engage in bores on cylinder block.
– Detach sleeve -T10053/1-.
– Screw in sealing flange bolts by hand as far as stop.
– Tighten securing bolts of sealing flange diagonally to speci‐
fied torque ⇒ page 66 .
– Install sump ⇒ page 186 .
– Install toothed belt (adjust valve timing) ⇒ page 152 .
Further installation is carried out in reverse order of removal.
Observe the following:
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ Crankshaft pulley bolt ⇒ Item 1 (page 139) (1)
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner
♦ ⇒ Running gear, axles, steering; Rep. gr. 44; Wheels, tyres;
Wheel change.

1.9 Renewing caps in cylinder block (pul‐


ley end)
Special tools and workshop equipment required

1. Cylinder block (pulley end) 77


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♦ Puller -T10055-

♦ Commercially available M8 nut


♦ Commercially available welding unit
♦ Commercially available hot air blower
Removing
– Remove motor ⇒ page 9 .
– Remove toothed belt ⇒ page 146 .
– Expose the cap to be renewed.

Note

Set the spot weld only on the outside of the nut to make sure
that the threads remain undamaged.

– Using commercially available welding unit, set two to three


spot welds -2- to secure M8 nut -3- centrally on cap -1-, and
allow bonds to cool.

– Screw puller -T10055- -1- into welded nut -2-.

78 Rep. gr.13 - Crankshaft group


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– Apply heat from commercially available hot air blower to cap


to liquefy the sealant.
– Pull cap -1- out of cylinder block using puller -T10055- -3-.
Installing
– Apply locking fluid to new cap in area of contact with crank‐
case ⇒ Electronic parts catalogue (ETKA).
– Use a suitable tool, e.g. T10266, along with a plastic ham‐
mer to drive new cap into crankcase until it is flush.

1. Cylinder block (pulley end) 79


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2 Cylinder block, gearbox end


⇒ o2.1 verview - cylinder block, gearbox end”, page 80
⇒ a2.2 nd installing flywheel”, page 83
⇒ a2.3 nd installing sealing flange on gearbox side”, page 85
⇒ c2.4 aps in cylinder block (gearbox end)”, page 95

2.1 Assembly overview - cylinder block, gearbox end

80 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Flywheel
❑ Removing and instal‐
ling ⇒ page 83
❑ Can only be fitted in
one position

Note

The flywheel is equipped with


centrifugal weights. The centri‐
fugal weights generate a »clack‐
ing sound« when the engine is
cranked by hand. The »clacking
sound« is generated by design and
there is no need to raise a com‐
plaint. When the cranking speed is
attained, the noise will disappear.

2 - Bolt
❑ Specified torque: ⇒ page 616
3 - Engine speed sender -G28-
❑ Assembly overview ⇒ page 616
4 - Sealing flange, gearbox side
❑ With shaft seal
❑ With sender wheel for engine speed sender -G28-.
❑ Renew after removal
❑ Removing and installing ⇒ page 85
5 - Bolt

2. Cylinder block, gearbox end 81


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Specified torque and tightening sequence: ⇒ page 82
6 - Dowel sleeve
❑ Qty. 2
7 - Intermediate plate
❑ Do not damage or bend when assembling.
❑ Installing ⇒ page 82
8 - Adapter
❑ Removing and installing ⇒ page 83
❑ Slide intermediate plate onto dowel sleeves ⇒ page 82
9 - Bolt
❑ Qty. 2
❑ For intermediate plate
❑ 25 Nm
10 - Bolt
❑ Qty. 8
❑ Renew after removal
❑ 60 Nm +90°

Installing intermediate plate

– Attach intermediate plate -1- to sealing flange -2- -arrow B-.


– Slide intermediate plate onto dowel sleeves -arrows A-.
Sealing flange on gearbox side - specified torque and tightening
sequence

– Tighten bolts in stages in the sequence shown.

82 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Stag Bolts Specified torque


e
1 -1 to 6- Screw in by hand as far as stop
2 -1 to 6- 13 Nm
Adapter

– Unscrew bolts -arrows- to remove.


– When installing, slide intermediate plate onto dowel sleeves
⇒ page 82 .
Component Specified torque
Bolts 25 Nm

2.2 Removing and installing flywheel


Special tools and workshop equipment required
♦ Counterhold -3067-

Removing
• Gearbox is removed.

Caution

Risk of damaging flywheel.


♦ Unscrew bolts by hand. Do not use pneumatic wrenches
or other power impact wrenches.
♦ When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.

– Insert counter-hold tool -3067- in hole on cylinder block


-item B-, loosen bolts for flywheel.

2. Cylinder block, gearbox end 83


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– Unscrew bolts -2-, and detach flywheel -1-.

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

Caution

Oil may start to escape if threaded holes in crankshaft are


not cleaned or not cleaned properly.
♦ Clean threaded holes in crankshaft of adhesive residue
and locking fluid.
♦ Make sure not to damage oil seal when cleaning.

– Clean crankshaft flange until adhesive and locking fluid resi‐


due is removed completely.
– Vacuum off loosened particles of locking fluid residue using
industrial vacuum cleaner – never blow them out with com‐
pressed air.
– Use commercially available wire brush to completely remove
any sealant residue from one of the flywheel bolts which was
unscrewed during removal.
– Screw the cleaned bolt -2- in and out the threaded hole of
crankshaft -1- until no more locking fluid residue comes out.

84 Rep. gr.13 - Crankshaft group


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– During the cleaning process, permanently hold an industrial


vacuum cleaner at the threaded connection in order to col‐
lect the locking fluid residue that comes out.
– Repeat cleaning process for all threaded holes of crankshaft.
– Remove oil residue using commercially available oil dissolv‐
ing agent.
– Use a cloth to clean the flange of the crankshaft. Crankshaft
threads must be free of oil and grease.

Caution

Risk of damaging flywheel.


♦ Mount flywheel in such a way that bolts align centrally
with holes.
♦ Screw in bolts by hand. Do not use pneumatic wrenches
or other power impact wrenches.

– Start flywheel bolts.


– Insert counter-hold tool -3067- in hole in cylinder block -A-
and tighten bolts.

Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 80

2.3 Removing and installing sealing flange


on gearbox side
Special tools and workshop equipment required

2. Cylinder block, gearbox end 85


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♦ Insert tool, 24 mm -V.A.G 1332/11-

♦ Assembly tool -T50010-

♦ Depth gauge -VAS 6082-

♦ M6 x 35 bolt, qty. 3
♦ M7 x 35 bolt, qty. 2
– Remove gearbox ⇒ Rep. gr. 34; Removing and installing
gearbox; Removing gearbox.
– Remove intermediate plate ⇒ page 83 .
– Remove flywheel ⇒ page 83 .

Note

For reasons of clarity, the following work procedures are shown


with the engine removed.

– Remove intermediate plate -1- from dowel sleeves


-arrows A-.

86 Rep. gr.13 - Crankshaft group


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– Guide intermediate plate -1- upwards.


– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Turn crankshaft at bolt for toothed belt pulley until crankshaft
is at “TDC” position as shown in illustration.

• Hole -2- in sender wheel -3- faces vertical ridge -1- on seal‐
ing flange.
– Remove sump ⇒ page 186 .
– Remove engine speed sender -G28- ⇒ page 622 .
Pressing out sealing flange with sender wheel

– Unscrew bolts -arrows- for sealing flange -1-.


– To press off, screw 3 bolts M6 x 35 into sealing flange -1-
-arrows-.

2. Cylinder block, gearbox end 87


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Note

The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.

– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel

Note

The sealing flange with a PTFE seal is equipped with a sealing


lip support ring -2-. This support ring serves as a fitting sleeve
and must not be removed prior to installation.

♦ Sealing flange and sender wheel -1- must not be separated


or turned after removal from packaging.
♦ The sender wheel -1- is held in its installation position on the
locating pin of the assembly tool -T50010-.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly tool -T50010- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

88 Rep. gr.13 - Crankshaft group


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Set-up of assembly tool -T50010-:

A - Clamping surface
B - Nut
C - Guide pin
D - Assembly housing
E - Hexagon socket head bolt (qty. 2)
F - Core
G - Locating pin
H - Knurled screw (qty. 3)
Mount sealing flange with sender wheel on assembly tool -
T50010-:

– Screw on nut -B- until just before it touches the clamping


surface -A- of the threaded spindle.
– Clamp assembly device -T50010- at clamping surface -A- of
threaded spindle in a vice -1-.

2. Cylinder block, gearbox end 89


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– Press down assembly housing -D- -arrow-. Assembly hous‐


ing must rest against nut -B-.
• Inner part -F- of assembly tool and assembly housing -D-
must be at same height.
– Place sealing flange with front side facing down on a clean
level surface.

• Do not take the sender wheel out of the sealing flange or


rotate it out of position.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against the flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.

– Place sealing flange -2- with front side facing downwards on‐
to assembly tool -T50010- so that locating pin -G- is seated
in hole -1- in sender wheel -3-.

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

90 Rep. gr.13 - Crankshaft group


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– Only the two knurled screws shown in this illustration can be


screwed in.
– Press sealing flange and sealing lip support ring -2- against
surface of assembly tool -T50010- whilst tightening knurled
screws.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel
remains fixed in assembly tool.
Mounting assembly tool -T50010- with sealing flange -1- on
crankshaft flange:

• The crankshaft flange must be free of oil and grease.


• Engine is at “TDC” position.
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool -T50010- in
-direction of arrow- until nut -B- rests against assembly
housing -D-.
– Align flat side of assembly housing to sealing surface of
cylinder block on sump side.
– Attach assembly tool -T50010- together with sealing flange
-2- to crankshaft flange -1-.

2. Cylinder block, gearbox end 91


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– To do this, screw hexagon socket head bolts -E- into crank‐


shaft flange (approx. 5 full turns) using a hexagon key -3-.
– Push guide pin -C- into crankshaft flange.
– To guide sealing flange -2-, screw two M6 x 35 bolts -item 1-
into cylinder block.

Bolting assembly tool -T50010- onto crankshaft flange:

– Push assembly housing -D- by hand in direction of -arrow-


until sealing lip support ring -2- rests against crankshaft
flange -1-.
– Make sure that guide pin -C- is properly seated in hole in
crankshaft. This ensures that the sender wheel reaches its
final installation position.
– Tighten the two hexagon socket head bolts of the assembly
tool -T50010- hand-tight with hexagon key-3-.
– Screw nut -B- onto threaded spindle by hand until nut rests
against assembly housing -D-.

92 Rep. gr.13 - Crankshaft group


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Pressing sender wheel onto crankshaft flange using assembly


tool -T50010-:

– Tighten nut -B- of assembly tool -T50010- to 35 Nm.


• After nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block -2- and sealing flange
-1-.
Checking sender wheel installation position on crankshaft:

– Screw on nut -B- until it reaches end of threaded spindle.


– Unscrew the two bolts -2- from cylinder block.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool -T50010- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.
– Position depth gauge -VAS 6082- on crankshaft flange -1-.

– Measure distance -a- between crankshaft flange -2- and


sender wheel -1-.

2. Cylinder block, gearbox end 93


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• Specification: dimension -a- = 0.5 mm


– If measured value is too low, press sender wheel further in ⇒
page 94 .
Re-pressing sender wheel:

– Secure assembly tool -T50010- on crankshaft flange.


– Make sure that locating pin of assembly tool -T50010- is
properly seated in sender wheel hole.
– Tighten the two hexagon socket head bolts -E- hand-tight
with hexagon key -3-.
– Push assembly tool -T50010- by hand against sealing flange
-1-.

– Screw nut -B- by hand onto threaded spindle until nut rests
against assembly tool -T50010-.
– Push guide pin -C- into crankshaft flange.
– To guide sealing flange -1-, screw two M6 x 35 bolts -item 2-
into cylinder block.
– Tighten nut -B- of assembly tool -T50010- to 40 Nm.

94 Rep. gr.13 - Crankshaft group


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– Check sender wheel installation position on the crankshaft


again ⇒ page 93 .
– If the measured value is too low, tighten nut of assembly tool
-T50010- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 93 .
Installing
Assembly is carried out in reverse sequence; note the following:
– Install sump ⇒ page 186 .
– Install intermediate plate ⇒ page 83 .
– Install flywheel ⇒ page 83 .
– Install intermediate plate ⇒ page 82 .
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 80
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ Fig. ““Sealing flange on gearbox side - specified torque
and tightening sequence”“, page 82
♦ ⇒ o1.1 verview - glow plug system”, page 616
♦ ⇒ Rep. gr. 34; Removing and installing gearbox; Specified
torques for gearbox

2.4 Renewing caps in cylinder block (gear‐


box end)
Special tools and workshop equipment required
♦ Puller -T10055-

♦ Commercially available M8 nut


♦ Commercially available welding unit

2. Cylinder block, gearbox end 95


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♦ Commercially available hot air blower


Removing
– Remove flywheel ⇒ page 83
– Expose the cap to be renewed.

Note

Set the spot weld only on the outside of the nut to make sure
that the threads remain undamaged.

– Using commercially available welding unit, set two to three


spot welds -2- to secure M8 nut -3- centrally on cap -1-, and
allow bonds to cool.

– Screw puller -T10055- -1- into welded nut -2-.

– Apply heat from commercially available hot air blower to cap


to liquefy the sealant.
– Pull cap -1- out of cylinder block using puller -T10055- -3-.
Installing
– Apply locking fluid to new cap in area of contact with crank‐
case ⇒ Electronic parts catalogue (ETKA).
– Use a suitable tool, e.g. T10266, along with a plastic ham‐
mer to drive new cap into crankcase until it is flush.

96 Rep. gr.13 - Crankshaft group


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Crankshaft
⇒ o3.1 verview - crankshaft”, page 97
⇒ d3.2 imensions”, page 97
⇒ n3.3 eedle bearing in crankshaft”, page 97
⇒ a3.4 xial clearance of crankshaft”, page 100

3.1 Assembly overview - crankshaft

WARNING

The crankshaft must not be loosened on engines with bal‐


ance shafts.
The correct alignment of the crankshaft with the balance
shafts cannot be established using workshop equipment.

3.2 Crankshaft dimensions


Honing Crankshaft Conrod bearing journal diameter
dimen‐ bearing journal in mm
sion diameter in mm
Basic di‐ 54.00 -0.022 50.90 -0.022
mension -0.042 -0.042

3.3 Renewing needle bearing in crankshaft


Only vehicles with a dual clutch gearbox
Special tools and workshop equipment required
♦ Counter support, e.g. KUKKO 22-1 -VAS 251 621-

♦ Internal puller -VAS 251 635-

3. Crankshaft 97
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♦ Pin -VW 207 C-

Note

♦ Vehicles with dual clutch gearbox, the needle bearing must


be installed in rear end of crankshaft.
♦ For vehicles with manual gearbox, no needle bearing must
be installed in the crankshaft.

Prerequisites:

• Gearbox is removed ⇒ Rep. gr. 34; Removing and installing


gearbox; Removing gearbox.
• Always renew needle bearing -arrow- after separating en‐
gine and gearbox.
• The front edges of the inner puller must be free of chips.

98 Rep. gr.13 - Crankshaft group


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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

Note

The inscribed side of an open needle bearing must be visible


when installed. Bearings which are sealed on one side must be
driven in with the sealed side facing the crankshaft.

– Clean bearing seat in crankshaft and apply as thin coating of


grease.
– Drive needle bearing into crankshaft to installation depth us‐
ing drift -VW 207 C-.
Installation depth: dimension -a- = 2.0 mm

3. Crankshaft 99
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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.

3.4 Measuring axial clearance of crank‐


shaft
Special tools and workshop equipment required
♦ Universal dial gauge holder -VW 387-

♦ Dial gauge -VAS 6079-

100 Rep. gr.13 - Crankshaft group


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Procedure

– Attach dial gauge -VAS 6079- with universal dial gauge hold‐
er -VW 387- to cylinder block as shown in illustration and set
against crankshaft.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off meas‐
ured value.
Axial clearance:
• New: 0.07 … 0.17 mm
• Wear limit: 0.37 mm

3. Crankshaft 101
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4 Pistons and conrods


⇒ o4.1 verview - pistons and conrods”, page 102
⇒ a4.2 nd installing pistons”, page 105
⇒ p4.3 iston projection at TDC”, page 107
⇒ p4.4 istons and cylinder bores”, page 109
⇒ n4.5 ew conrod”, page 111
⇒ r4.6 adial clearance of conrods”, page 112

4.1 Assembly overview - pistons and conrods

Note

Oil spray jet and pressure relief valve ⇒ page 105 .

102 Rep. gr.13 - Crankshaft group


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1 - Bolts
❑ Oil threads and contact
surface
❑ Renew after removal
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ The conrod bearing cap
only fits in one posi‐
tion and only on the
appropriate conrod due
to the breaking proce‐
dure (cracking) sepa‐
rating the cap from the
conrod.
❑ Mark conrod and cylin‐
der allocation in colour
-B-
❑ Installation position:
markings -A- face to‐
wards belt pulley end.
3 - Bearing bushes
❑ Fitting position ⇒ page
104
❑ Renew worn bearing
shells
❑ Note version: upper
bearing shell (towards
piston) made of a more
wear-resistant material.
Identification on new
bearing shells: black
line on bearing surface
in area of joint
❑ Ensure firm seating
4 - Connecting rod
❑ With industrially cracked conrod bearing cap
❑ Renew as set only.
❑ Mark conrod bearing cap and cylinder allocation in colour -B-
❑ Axial clearance, wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 112
❑ Separate new conrod ⇒ page 111 .
❑ Installation position: markings -A- towards belt pulley end
5 - Retaining ring
❑ Qty. 2
❑ Renew after removal
6 - Piston pin
❑ Removing and installing ⇒ page 105
7 - Piston
❑ With combustion chamber.
❑ Renew piston if cracks are visible on piston crown or piston skirt
❑ Mark installation position and cylinder number ⇒ page 104 .
❑ Removing and installing ⇒ page 105

4. Pistons and conrods 103


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❑ Checking piston and cylinder bore ⇒ page 109
❑ Measuring piston projection at “TDC” ⇒ page 107
8 - Compression rings
❑ Measuring ring gap ⇒ page 110
❑ Measuring ring-to-groove clearance ⇒ page 111
❑ Use commercially available piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gaps by 120°
9 - Oil scraper ring
❑ Measuring ring gap ⇒ page 110
❑ Measuring ring-to-groove clearance ⇒ page 111
❑ Use piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Offset gap 120° relative to lower compression ring

Installation position and allocation of piston to cylinder

Caution

Risk of damage to piston crown.


♦ If worn pistons are to be reinstalled, use paint to mark
their allocation to cylinder on piston crown. Do not use
indentation, scratches, notches, or similar to mark piston
crown.

• Arrow on piston crown points to pulley end -arrow-.


Installation position of bearing shells in conrods

104 Rep. gr.13 - Crankshaft group


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– Centre bearing shells on conrod and on conrod bearing cap.


• Dimension -a- = 2.5 mm.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve


2- Oil spray jet (for cooling of pistons)
Bolts Specified torque
Bolt with pressure 27 Nm
relief valve
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.

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.

4.2 Removing and installing pistons


Special tools and workshop equipment required

4. Pistons and conrods 105


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♦ Pin -VW 222 A-

♦ Piston ring clamp, commercially available


Removing
– Remove cylinder head ⇒ page 120 .
– Remove oil pump ⇒ page 191 .
– Mark installation position and allocation of conrod bearing
caps to cylinder and conrods as an aid for reinstalling ⇒ Item
2 (page 103) .
– Unscrew conrod bearing cap.
– Withdraw piston upwards together with conrod.

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 piston ring clamp.
Installation position:
• Piston ⇒ page 104 .
• Bearing shells in conrods ⇒ page 104 .
– Install conrod bearing cap in accordance with marking.
– Install oil pump ⇒ page 191 .
– Install cylinder head ⇒ page 120 .
Specified torques
♦ ⇒ o4.1 verview - pistons and conrods”, page 102

106 Rep. gr.13 - Crankshaft group


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4.3 Measuring piston projection at TDC

Note

♦ When installing new pistons or a short engine, check piston


projection at “TDC”.
♦ If you have measured the piston projection and it is not
same for all pistons, use the highest value to allocate the
cylinder head gasket.
♦ Install the appropriate cylinder head gasket depending on
piston projection, according to following table.

Special tools and workshop


equipment required

♦ Measuring bridge -VW 382/7- from measuring tool -VW 382-


♦ Measuring plate -VW 385/17- from universal measuring tool
-VW 385-
♦ Dial gauge -VAS 6079-

4. Pistons and conrods 107


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Procedure

– Secure dial gauge -VAS 6079- with measuring bridge -


VW 382/7- and measuring plate -VW 385/17- to cylinder
block as shown in the illustration.
– Measure the projection of each piston at the two points
marked with -arrows- (at the rear side and front side of the
piston seen in the longitudinal direction of the engine).
– Install the appropriate cylinder head gasket depending upon
piston projection, according to following table:
Piston projection over upper Identification
edge of cylinder block (No. of holes)
mm
0.91 to 1.00 1
1.01 to 1.10 2
1.11 to 1.20 3
Cylinder head gasket identification

1- Part number

108 Rep. gr.13 - Crankshaft group


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2- Ignore
3- Holes

Note

If the measured values for piston projection are not the same
for all pistons, use the highest value to determine the correct
cylinder head gasket size.

4.4 Checking pistons and cylinder bores


Checking piston

– Measure approx. 15 mm from lower edge, offset 90° from


piston pin axis with a 75 to 100 mm external micrometer.
• Maximum deviation from nominal dimension: 0.04 mm.

Note

♦ Check piston skirt coating for wear. Also check pistons and
cylinder bores for carbon deposits in general.
♦ Piston must be changed if piston shaft reveals cracking.

Piston diameter, mm
Specification 80.921)
• 1)Dimensions include coating (thickness 0.02 mm). The
coating will wear down.

Measuring cylinder bore

4. Pistons and conrods 109


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– Using cylinder gauge -VAS 6078- take measurements at 3


positions diagonally in lateral direction -A- and longitudinal
direction -B-.
• Maximum deviation from nominal dimension: 0.10 mm.

Note

Check cylinder wall for wear of honed surfaces, scratches and


other defects.

Cylinder bore diameter, mm


Specification 81.03

Note

Do not measure cylinder bores when cylinder block is mounted


on engine and gearbox support -VAS 6095-, as measurements
may be incorrect.

Measuring piston ring gap

– Push piston ring at right angles to cylinder wall from above


down into cylinder bore to approx. 15 mm from bottom end
of cylinder.
– Push in using a piston without piston rings.

110 Rep. gr.13 - Crankshaft group


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Piston ring New Wear limit


mm mm
1st compression ring 0.30 to 0.40 0.55
2nd compression ring 0.20 to 0.45 0.95
Oil scraper ring 0.25 to 0.50 0.75
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.


Piston ring New Wear limit
mm mm
1st compression ring 0.06 to 0.09 0.08
2nd compression ring 0.05 to 0.08 0.08
Oil scraper ring 0.03 to 0.06 0.08

4.5 Separating new conrod


Separating new conrods

On new conrods it is possible that conrod and conrod bearing


cap are very firmly bonded. Proceed as follows if the conrod
bearing cap cannot be removed by hand:
– To avoid damage, gently clamp conrod in a vice with protec‐
tion jaws, as shown in illustration.
• Clamp conrod below dashed line.
– Unscrew bolts -arrows- around 5 turns.
– Using a plastic hammer, carefully knock against conrod
bearing cap -arrow- until it is loose.

4. Pistons and conrods 111


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4.6 Checking radial clearance of conrods


Special tools and workshop equipment required
♦ Plastigage
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten to 30 Nm (without turning
further angle).
– Do not rotate crankshaft while doing so.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm.
– Renew conrod bolts.

112 Rep. gr.13 - Crankshaft group


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15 – Cylinder head, valve gear


1 Cylinder head
⇒ o1.1 verview - cylinder head”, page 113
⇒ o1.2 verview - cylinder head cover”, page 117
⇒ a1.3 nd installing cylinder head”, page 120
⇒ a1.4 nd installing cylinder head cover”, page 126
⇒ a1.5 nd installing injector seals”, page 129
⇒ a1.6 nd installing camshaft housing”, page 131
⇒ c1.7 ompression”, page 135

1.1 Assembly overview - cylinder head

1. Cylinder head 113


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1 - Bolt
❑ 20 Nm
2 - Engine lifting eye
3 - Bracket
4 - Bolt
❑ Qty. 3
❑ 20 Nm
5 - Bolt
❑ 10 Nm
6 - Union
❑ For coolant hoses
7 - Seal
❑ Renew after removal
8 - Dowel pin
❑ For camshaft housing
9 - Dowel pin
❑ For intake manifold
10 - Cylinder head
❑ Removing and instal‐
ling ⇒ page 120
❑ To prevent damage
to glow plugs, always
place cylinder head on
a soft foam surface af‐
ter removal.
❑ Check for distortion ⇒
page 115 .
❑ Must not be reworked.
❑ Before installing, check
that the two dowel
sleeves for centring cylinder head on cylinder block are fitted.
❑ Information on plug ⇒ page 115

Note

Valve seats must not be reworked


due to the very small tolerances.
Only lapping-in is permitted.

11 - Spacer ring
❑ Renew if damaged
12 - O-ring
❑ Moisten with coolant
❑ Renew after removal
13 - Radiator outlet coolant -G62-
❑ Removing and installing ⇒ page 285
14 - Bolt
❑ 8 Nm
15 - Cylinder head gasket
❑ Renew after removal ⇒ page 120

114 Rep. gr.15 - Cylinder head, valve gear


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❑ Cylinder head gasket identification ⇒ page 115
16 - Cylinder block
17 - Washer
18 - Bolt
❑ Renew after removal
❑ Sequence when loosening ⇒ page 122 .
❑ Specified torque and tightening sequence: ⇒ page 116

Plug in cylinder head:

Note

♦ There is a plug with a seal in the cylinder head on the gear‐


box end (not illustrated).
♦ M10x18 plug.
♦ Specified torque: 15 Nm.
♦ For allocation, refer to ⇒ Electronic Parts Catalogue

Checking cylinder head for distortion

– Use straight edge 500 mm -VAS 6075- and feeler gauge to


measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm

Note

Cylinder heads for TDI engines must not be reworked.

Cylinder head gasket identification

1. Cylinder head 115


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1- Part number
2- Ignore
3- Holes

Note

Different thicknesses of cylinder head gasket are fitted depend‐


ing on the piston projection ⇒ page 107 . If only cylinder head
gasket is removed, install a new cylinder head gasket with
same identification.

Cylinder head - specified torque and sequence

Note

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

– Tighten bolts in stages in the sequence shown.

116 Rep. gr.15 - Cylinder head, valve gear


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Stage Bolts Specified torque/turning further angle


1 -1 to 10- 30 Nm
2 -1 to 10- 70 Nm
3 -1 to 10- Turn 90° further
4 -1 to 10- Turn 90° further
5 -1 to 10- Turn 90° further

1.2 Assembly overview - cylinder head


cover
⇒ o1.2.1 verview - cylinder head cover”, page 117
⇒ o1.2.2 verview - cylinder head cover with add-on parts”, page
119

1.2.1 Assembly overview - cylinder head cover

1. Cylinder head 117


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1 - Seal
❑ Renew if damaged or
leaking
2 - Cylinder head cover
❑ Removing and instal‐
ling ⇒ page 126
❑ With seal for injector ⇒
Item 7 (page 418)
❑ Renew seal after each
removal ⇒ page 129
3 - Grommet
❑ In cylinder head cover
4 - Clamping piece
❑ Fitting position ⇒ page
419
5 - Bolt
❑ Specified torque: ⇒
page 417
6 - Fuel return line
❑ Remove ⇒ page 434
7 - Injector
❑ Comply with rules for
cleanliness ⇒ page 7
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 417
8 - O-ring
❑ Renew after removal
9 - Heat shield seal
❑ Renew after removal
10 - Seal
❑ In cylinder head cover for injectors
❑ Renew after removal ⇒ page 129
11 - Hose
❑ For crankcase ventilation.
❑ Press release buttons to detach
Installing:
♦ Initially, install on intake hose
♦ Catch must engage audibly when installing
♦ Turn breather hose so that it can be fitted onto connection on cylinder head cover
♦ Fit to cylinder head cover, and engage it audibly
12 - O-ring
❑ Renew after removal
13 - Cap
14 - Seal
❑ For sealing cover
15 - Grommet

118 Rep. gr.15 - Cylinder head, valve gear


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16 - Bolt
❑ Renew gasket if damaged
❑ Specified torque and tightening sequence: ⇒ page 119

Cylinder head cover - specified torque and tightening sequence

– Tighten cylinder head cover bolts in the sequence -1 to 7-.


Bolts Specified torque
-1 to 7- 9 Nm

1.2.2 Assembly overview - cylinder head cover with add-on parts

1. Cylinder head 119


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1 - Pressure accumulator
2 - Bolt
❑ 8 Nm
3 - Nut
❑ 8 Nm
4 - Bracket
❑ For -G450- and -G505-
5 - Bolt
❑ 8 Nm
6 - Support
7 - Bolt
8 - Centre hex stud
❑ 8 Nm
9 - Cylinder head cover
❑ Removing and instal‐
ling ⇒ page 126
10 - Heat shield
11 - Bolt

1.3 Removing and installing cylinder head


Special tools and workshop equipment required
♦ Release lever -80 - 200-

120 Rep. gr.15 - Cylinder head, valve gear


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♦ Spring-type clip pliers -VAS 6362-

Removing

Note

♦ Attach all heat-shielding sleeves in the same places when


installing.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Remove exhaust manifold with low-pressure turbocharger ⇒


page 614 .
– Remove camshaft housing ⇒ page 131 .
– Remove intake manifold ⇒ page 450 .
– Release connector -3-, pull it off, and detach it from cover
-2-.

– Unscrew bolt -1- and remove cover.


– Unscrew bolt -7-.

1. Cylinder head 121


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– Pull out bolt slightly.


– Loosen cylinder head bolts in the sequence -1 … 10-.

Note

♦ A second mechanic is required to remove the cylinder head.


♦ Avoid any damage to the cylinder head and valves. Place
the cylinder head on a soft foam surface.

– Unscrew nut for tensioning roller ⇒ Item 6 (page 139) .


– Swing cylinder head towards left out of rear toothed belt
guard and simultaneously remove tensioning roller.
– Remove cylinder head, and place it on a soft surface. Use a
suitable foam surface for this.
– Remove any coolant residue on the pistons and cylinder wall
immediately with a cloth.

122 Rep. gr.15 - Cylinder head, valve gear


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– Make sure that no components are damaged. Place cylinder


head safely to one side, using a wooden block as a support
if necessary.

Caution

Risk of damage to glow pins when cylinder head is lowered.


♦ After removal, the cylinder head must not be put down
on the sealing surface with the glow plugs still installed
because the glow plugs project slightly beyond the seal‐
ing surface.

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

Note

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


pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
♦ Discolouration (dark spots, see photo) need not be removed.

♦ When removing the sealant residue, make sure no loose


particles get into the open channels of the engine.
♦ Ensure that all adjacent workspaces are clean, and that
none of the above mentioned sanding or abrasive media are
used.
♦ Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the
turbocharger or the conrod bearings.

– Only remove sealant residue from cylinder head and cylinder


block using scraper -VAS 852 005- or a commercially availa‐
ble ceramic glass scraper.
• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt pockets.
• Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
roller rocker fingers and running surface of cam must be
oiled.

1. Cylinder head 123


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• Handle the cylinder head gasket very carefully to prevent


damage to the silicone coating or the indented area of the
gasket.
• Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
• When the cylinder head or cylinder head gasket is renewed,
the entire coolant and the engine oil must be changed.
– Remove any loose remains using a lint-free cloth.
– Before fitting cylinder head, remove crankshaft stop -
T10490- and turn crankshaft against normal direction of ro‐
tation until all pistons are positioned approximately equally
below “TDC”.
– If no dowel sleeves for centring cylinder block and cylinder
head are fitted, install dowel sleeves.
– Note cylinder head gasket identification:

1- Part number
2- Ignore
3- Holes

Note

♦ If the cylinder head gasket or cylinder head has been re‐


placed, select a new cylinder head gasket according to the
number of holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be determined by measuring
the piston projection at “TDC” ⇒ page 107 .

– Fit cylinder head gasket on dowel sleeves -arrows- in cylin‐


der block.

124 Rep. gr.15 - Cylinder head, valve gear


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• Cylinder head gasket installation position: marking “top” or


part number towards cylinder head

Note

♦ A second mechanic is required to fit the cylinder head.


♦ After repair work it is not necessary to retighten the cylinder
head bolts.

– Fit cylinder head.


– Fit and tighten cylinder head bolts ⇒ page 116 .
– Then turn the crankshaft in direction of engine rotation until
the pin -arrow- on the crankshaft stop -T10490- engages in
the sealing flange as the crankshaft rotates.

– Install toothed belt (adjust valve timing) ⇒ page 152 .


Further installation is carried out in reverse order of removal.
Observe the following:
– Install emission control module ⇒ page 523 .
– Install front exhaust pipe ⇒ page 501 .
– Install coolant pipes ⇒ page 298 .
– Route wires ⇒ Electrical system; Rep. gr. 97; Relay carriers,
fuse carriers, electronics boxes; Overview of fitting locations
- relay carriers, fuse carriers, electronics boxes and ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting loca‐
tions.
– Fit engine cover panel ⇒ page 61 .
– Change engine oil ⇒ Maintenance; Booklet .

1. Cylinder head 125


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Caution

If a new cylinder head has been installed, the cooling system


must be flushed and the coolant must be renewed to ensure
optimum surface protection ⇒ page 237 .

If the existing cylinder head has been installed:


– Add coolant ⇒ page 215 .

Note

♦ After new components have been installed (engine/short en‐


gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

Specified torques
♦ ⇒ o1.1 verview - cylinder head”, page 113
♦ ⇒ o1.2 verview - cylinder head cover”, page 117
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ o5.1 verview – intake manifold”, page 447
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ o2.2 verview - toothed belt”, page 138
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o3.1 verview - coolant pipes”, page 294

1.4 Removing and installing cylinder head


cover
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

126 Rep. gr.15 - Cylinder head, valve gear


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♦ Spring-type clip pliers -VAS 6362-

Removing

Note

Reinstall the heat insulation sleeve in the same location when


assembling.

– Remove engine cover panel ⇒ page 61 .


– Remove upper part of toothed belt guard ⇒ page 140 .
– Removing high-pressure accumulator ⇒ page 437 .
– Remove injectors ⇒ page 417 .

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Unscrew bolts -arrows-.

1. Cylinder head 127


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– Pull heat protection hose towards rear.


– Clamp off coolant hose -2- with hose clamps up to 25 mm
-3094-.
– Open clip -3-, and pull coolant hose off turbocharger.
– Lay coolant line -1- to one side.
– Unscrew bolts -arrows- on low-pressure turbocharger -1-.

– Push vacuum lines to one side.


– Open heat insulation sleeves -4- and -5-.

– Release connectors -3-, pull them off, and lay wiring harness
to one side.
– Unscrew nut -arrow B-.
– Unscrew bolt -arrow A-.
– Lay vacuum reservoir -1- with lines connected to one side.
– Unscrew bolts -arrows C-.
– Move retainer with pressure differential senders -2- towards
rear.

128 Rep. gr.15 - Cylinder head, valve gear


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– Loosen and unscrew bolts for cylinder head cover in the


sequence -7- to -1-.

– Remove cylinder head cover.


– Remove add-on parts ⇒ page 119 .
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew O-ring.
♦ Renew gasket and bolts for cylinder head cover if damaged
or leaking.

– Fit engine cover panel ⇒ page 61 .


Specified torques
♦ ⇒ Fig. ““Cylinder head cover - specified torque and tighten‐
ing sequence”“, page 119
♦ ⇒ o1.2 verview - cylinder head cover”, page 117
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o3.1 verview - injectors”, page 417
♦ ⇒ o3.2 verview - fuel rail”, page 419

1.5 Removing and installing injector seals


Special tools and workshop equipment required

1. Cylinder head 129


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♦ Yoke -3390-

♦ Tool set -T10133C-

♦ Seal puller -T40195-

Procedure
– Remove corresponding injector ⇒ page 417 .
– Twist oil seal extractor -T40195- into oil seal -1-.

– Place impact hammer -T10133/3- together with adapter -


T10133/2- in position on oil seal extractor as shown in the

130 Rep. gr.15 - Cylinder head, valve gear


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illustration and then pull out upwards using tapping move‐


ments.
– Press in new seal for injector using carrier -3390- and short
extension -1- from top to stop.

1.6 Removing and installing camshaft


housing
Special tools and workshop equipment required
♦ Hand drill with plastic brush attachment
♦ Safety glasses
♦ Sealant ⇒ Electronic Parts Catalogue
♦ Applicator gun -VAS 6966-

Note

♦ Attach all heat-shielding sleeves in the same places when


installing.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

1. Cylinder head 131


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Removing
– Remove air pipe ⇒ page 382 .
– Unscrew bolt -3- and move bracket -2- aside.

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


– Remove toothed belt from camshaft ⇒ page 161 .
– Remove fuel rail ⇒ page 437 .
– Remove cylinder head cover ⇒ page 126 .
– Release and pull off connector -2- for Hall sender -G40-.

– Loosen bolts for camshaft housing in the sequence -15 to 1-.

132 Rep. gr.15 - Cylinder head, valve gear


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– Unscrew bolts, carefully release camshaft housing from bon‐


ded joint and remove it.
Installing

Caution

Danger of soiling lubrication system and bearings.


♦ Cover open parts of engine.

WARNING

Risk of eye injury.


♦ Wear safety goggles.

– Remove remaining sealant from cylinder head and camshaft


housing using rotating plastic brush or similar.
– Remove any oil and grease from sealing surfaces.

Note

Indicate the use-by-date of the sealant.

– Cut off nozzle on tube at front marking (∅ of nozzle approx.


1.5 mm).

1. Cylinder head 133


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Caution

Risk of soiling of camshaft bearings through excess sealant.


♦ Do not apply sealant beads thicker than specified.

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


camshaft housing as shown in illustration.
– If necessary, use applicator gun -VAS 6966- to apply seal‐
ant.
• Thickness of sealant beads: 2 mm.

Note

♦ The camshaft housing must be installed within 5 minutes


after sealant is applied.
♦ After installing the camshaft housing, wait about 30 minutes
for the sealant to dry.

– Carefully fit camshaft housing on cylinder head, paying at‐


tention to dowel pins.
– Tighten bolts for camshaft housing ⇒ page 169 .
Further installation is carried out in reverse order of removal.
Observe the following:
– Install oil seal for camshaft ⇒ page 170 .
– Install cylinder head cover ⇒ page 126 .
– Install toothed belt (adjust valve timing) ⇒ page 152 .

134 Rep. gr.15 - Cylinder head, valve gear


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Caution

Avoid damage to valves and piston crowns after working on


valve gear.
♦ Because hydraulic compensation elements have to set‐
tle, engine must not be started for approx. 30 minutes
after installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to en‐
sure that none of the valves make contact when the
starter is operated.

Note

♦ After new components have been installed (engine/short en‐


gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

Specified torques
♦ ⇒ Fig. ““Camshaft housing - specified torque and tightening
sequence”“, page 169
♦ ⇒ o1.2 verview - cylinder head cover”, page 117
♦ ⇒ o3.2 verview - fuel rail”, page 419

1.7 Checking compression


Special tools and workshop equipment required
♦ T-bar and socket -3220-

1. Cylinder head 135


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♦ Compression tester -V.A.G 1763- with adapter -V.A.G


1763/8-

Procedure

• Engine oil temperature approx. 80°C.


• Battery voltage at least 12.5 V.
– Remove engine cover panel ⇒ page 61 .
– Unplug electrical connector on fuel pressure regulating valve
-N276- -item 2-.
– Start engine briefly to reduce fuel pressure in fuel rail.
– Remove all glow plugs ⇒ page 617 .
– Screw in adapter -V.A.G 1763/8- in place of corresponding
glow plug and connect compression tester -V.A.G 1763-.

Note

For information on how to use the compression tester, see the


⇒ operating instructions.

136 Rep. gr.15 - Cylinder head, valve gear


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– Have a 2nd mechanic operate starter until tester shows no


further pressure increase.
– Repeat procedure on each cylinder.
Compression pressures bar
New 25.0 to 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Installing
Assembly is carried out in reverse sequence; note the following:
– Entries will have been made in the event memory of the
engine control unit because connectors were separated and
the engine was started: Read event memory ⇒ Vehicle di‐
agnostic tester.

1. Cylinder head 137


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2 Toothed belt drive


⇒ o2.1 verview - toothed belt cover”, page 138
⇒ o2.2 verview - toothed belt”, page 138
⇒ a2.3 nd installing toothed belt guard”, page 140
⇒ a2.4 nd installing toothed belt”, page 146
⇒ t2.5 oothed belt from camshaft”, page 161

2.1 Assembly overview - toothed belt cover

1 - Lower toothed belt guard


❑ Removing and instal‐
ling ⇒ page 144
2 - Bolt
❑ With shoulder
❑ Captive in lower tooth‐
ed belt guard
❑ 12 Nm
3 - Heat shield
4 - Bolt
❑ 5 Nm
5 - Bracket
❑ For coolant lines from
injector for reducing
agent -N474-
6 - Upper toothed belt guard
❑ Removing and instal‐
ling ⇒ page 140
7 - Bolt
❑ 12 Nm
8 - Bracket
9 - Rear toothed belt guard
❑ To remove, remove
coolant pump ⇒ page
277 .

2.2 Assembly overview - toothed belt

138 Rep. gr.15 - Cylinder head, valve gear


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1 - Bolt
❑ Renew after removal
❑ Loosen and tighten with
counterhold -3415-
❑ Do not additionally oil
the thread and shoulder
❑ 180 Nm +135° (tighten‐
ing with turning further
angle can be performed
in stages, e.g. 90° +
45°)
2 - Crankshaft pulley
❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in
one position
3 - Nut
❑ 20 Nm
4 - Idler roller
5 - Stud
❑ 15 Nm
❑ Renew only if damaged
6 - Nut
❑ Renew after removal
❑ 20 Nm +45°
7 - Tensioning pulley
8 - Stud
❑ 15 Nm
❑ Renew only if damaged
9 - Toothed belt
Volkswagen Technical Site: https://vwts.ru
❑ Before removing, mark direction of rotation with chalk or felt-tipped marker pen.
❑ Check for wear
❑ Removing ⇒ page 146
❑ Installing (adjusting valve timing) ⇒ page 152
10 - Bolt
❑ Use counterhold tool -T10172- with adapters -T10172/11- to loosen and tighten
❑ Do not additionally oil the thread and shoulder
❑ 100 Nm
11 - Locating bolt
❑ 9 Nm
12 - Camshaft toothed belt pulley
❑ Contact surface between sprocket and camshaft must be free of oil
13 - Follower for camshaft
14 - Bolt
❑ 20 Nm
15 - Idler roller

2. Toothed belt drive 139


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16 - High-pressure pump
❑ Assembly overview ⇒ page 488
17 - Hub for high-pressure pump
❑ Assembly overview ⇒ page 488
❑ Contact surface between hub and toothed belt sprocket must be free of oil
18 - High-pressure pump toothed belt pulley
❑ Assembly overview ⇒ page 488
❑ Contact surface between hub and toothed belt sprocket must be free of oil
19 - Nut
❑ Do not additionally oil the thread and shoulder
❑ Use counter-hold tool -T10051- to loosen and tighten
❑ Specified torque ⇒ page 488
20 - O-ring
❑ Renew after removal
❑ Moisten with coolant
21 - Coolant pump
❑ Removing and installing ⇒ page 277
22 - Bolt
❑ Renew after removal
❑ 20 Nm +45°

2.3 Removing and installing toothed belt


guard
⇒ a2.3.1 nd installing upper toothed belt guard”, page 140
⇒ a2.3.2 nd installing lower toothed belt guard”, page 144

2.3.1 Removing and installing upper toothed


belt guard
Removing
– Remove engine cover panel ⇒ page 61 .
– Open plug-in connectors -A- and -B- for fuel lines and pull
off fuel lines. Disconnect plug-in connectors ⇒ Rep. gr. 20;
Plug-in connectors; Disconnecting plug-in connectors.

– Release and pull off connector -2- on coolant expansion


tank.

140 Rep. gr.15 - Cylinder head, valve gear


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– Unclip, release and pull off connector -4-.


– Free off electrical wire.
– Unclip retainer for fuel lines on coolant expansion tank
-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Unbolt fuel filter, and place it on engine with lines connected
⇒ Rep. gr. 20; Fuel filter; Removing and installing fuel filter.
– Remove injector for reducing agent -N474- on emission con‐
trol module with coolant hoses connected ⇒ page 559 .
– Unscrew bolt -4-.

– Unclip coolant lines -3- on toothed belt guard -1- from retain‐
ers -arrows-.
– Unclip lines -2- from retainer -arrow- at top.
– Remove injector for reducing agent -N474-, and lay it to one
side with lines connected.
– Open hose clip -arrow A-.

2. Toothed belt drive 141


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– Pull hose off emission control module.


– Push Torx screwdriver -3- into line -1-.

– Carefully bend line upwards in -direction of arrow-.


– Release catches -arrows-, disengage toothed belt cover (top
section) -1- and detach.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

142 Rep. gr.15 - Cylinder head, valve gear


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– Push Torx screwdriver -3- into line -1-.


– Carefully bend line downwards.
– Dimension -a- between the line and the toothed belt guard
must be approx. 2.3 cm.
– Carefully bend down retainer -arrow-. Use a plastic drift for
this.
– Make sure the lines are properly seated in the retainers
-arrows-.

– The left retainer must be seated on guide -5-.


– Bleed fuel system ⇒ page 410 .
Specified torques
♦ ⇒ o3.9 verview - injector for reducing agent”, page 566
♦ ⇒ Rep. gr. 20; Fuel filter; Assembly overview - fuel filter
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ a3.1 nd installing engine cover”, page 61

2. Toothed belt drive 143


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2.3.2 Removing and installing lower toothed


belt guard
Removing

Note

♦ To simplify the manufacturing process in the production fa‐


cilities the lower toothed belt guard is provided with a guide
at bottom which engages in the sealing flange. When remov‐
ing the toothed belt guard with engine support installed, the
guide in the toothed belt guard must be destroyed.
♦ Bear in mind that there are different versions!

– Remove vibration damper ⇒ page 69 .

Caution

Carry out the following work step with particular care. If the
toothed belt is damaged, damage to the engine may result.

– If a toothed belt guard version which is about to be discon‐


tinued is fitted, drill a hole according to the following dimen‐
sions:

♦ Dimension -a- = 10 mm
♦ Diameter: 8 mm
– Insert a screwdriver through drilled hole and break off guide
lug of toothed belt guard towards rear.
– If a more recent toothed belt guard version is fitted, insert
screwdriver into slot in guide lug.

144 Rep. gr.15 - Cylinder head, valve gear


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– Then, break off guide lug by turning screwdriver in


-direction of arrow-.
– Unscrew bolts -arrows-.

– Remove lower toothed belt guard -1-.


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

Note

If a new toothed belt guard is installed, the guide lug -arrow-


must be cut off prior to installing.

Guide lug on toothed belt guard

– Fit toothed belt guard. Note dowel pin -arrow- while doing
so.

– Bolt on toothed belt guard.


– Install vibration damper ⇒ page 69 .

2. Toothed belt drive 145


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Specified torques
♦ ⇒ o2.1 verview - toothed belt cover”, page 138

2.4 Removing and installing toothed belt


Special tools and workshop equipment required
♦ Diesel injection pump locking pin -3359-

♦ Counterhold -T10051-

♦ Counterhold -T10172- with adapters -T10172/11-

♦ Angle driver -T10264-

146 Rep. gr.15 - Cylinder head, valve gear


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Locking tool -T10265-

♦ Locking pin -T10492-

♦ Crankshaft stop -T10490-

♦ Torque wrench -V.A.G 1410-

2. Toothed belt drive 147


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♦ Ring spanner -T10024-

Note

The flywheel is equipped with centrifugal weights. The centrifu‐


gal weights generate a »clacking sound« when the engine is
cranked by hand. The »clacking sound« is generated by design
and there is no need to raise a complaint. When the cranking
speed is attained, the noise will disappear.

Removing
– Remove upper part of toothed belt guard ⇒ page 140 .
– Remove engine support ⇒ page 72 .
– Remove lower toothed belt guard ⇒ page 144 .

Caution

Risk of destruction due to toothed belt jumping.


♦ Only turn crankshaft in engine direction of rotation.

– Turn crankshaft by bolt for crankshaft pulley until camshaft


pulley is at “TDC”.
– Lock camshaft hub with diesel injection pump locking pin
-3359-; to do so, insert locking pin into fork on actuating arm
-2- and into hole -1- behind it in cylinder head.

– Loosen locking pin -1- in camshaft sprocket one half turn,


but do not remove.

148 Rep. gr.15 - Cylinder head, valve gear


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– Lock crankshaft sprocket in position with crankshaft stop


-T10490-.

• Pins of crankshaft stop -T10490- must engage in threaded


holes of toothed belt sprocket.
• Locking pin of crankshaft stop -T10490- must engage in hole
on sealing flange.

Caution

It is essential that the torque for loosening and tightening


the central bolts on camshaft and high-pressure pump is not
transferred to the respective locking pin. Otherwise the »fol‐
lower« may be damaged even if a counterhold is used.
These defects may not be noticed and may result in damage
to the engine. Therefore, pull out locking pin for loosening
and tightening the central bolt and reinsert the locking after‐
wards if necessary.

– Pull out locking pin, and slightly loosen bolt for camshaft.
Before loosening completely, insert locking pin back in.
– Loosen bolt -arrow- for camshaft pulley.

2. Toothed belt drive 149


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– To do this, use counterhold -T10172- with adapters -


T10172/11-.
– Lock high-pressure pump hub in position using locking pin
-T10492- -3-.

– To do this, insert locking pin into fork -2- on hub and into
hole -1- behind it in ancillary bracket.
– Turn locking pin -T10492- -B- until straight edge points to
right as shown.

– Apply counter-hold tool -T10051- -A-.


– Pull out locking pin, and slightly loosen nut for high-pressure
pulley. Before loosening completely, insert locking pin back
in.
– Loosen nut -arrow- for high-pressure pump pulley by approx.
90°.
– Loosen nut -1- for belt tensioner.

150 Rep. gr.15 - Cylinder head, valve gear


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– Turn eccentric of tensioning roller anti-clockwise -arrow- us‐


ing angle driver -T10264-, until the tensioning roller can be
locked with locking tool -T10265-.
– Turn belt tensioner eccentric clockwise -arrow- to stop using
special wrench, long reach -T10264-.

– Tighten nut -1- by hand.

Caution

Risk of irreparable damage if direction of rotation is reversed


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

– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.

2. Toothed belt drive 151


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Installing (adjusting valve timing)

Note

The installed tensioning rollers -A and B- differ from each other.

♦ The adjustment jig -1- is the distinguishing feature.


♦ The tensioning roller -A- is not locked in position using lock‐
ing tool -T10265-.
♦ Instead, the angle driver 8mm -T10409- must be used for
tensioning.
♦ Apart from that the procedure is identical.

Note

For adjusting work on the toothed belt, the engine must be cold.

Caution

Avoid damage to valves and piston crowns.


♦ When turning camshaft, crankshaft must be positioned
so that no piston is positioned at “TDC”.

Prerequisites:

152 Rep. gr.15 - Cylinder head, valve gear


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• Tensioning roller -B- locked with locking tool -T10265- and


secured to right stop with nut -1-.
• Metal lug -arrow- of tensioning roller must engage in cast
recess on cylinder head.

• Camshaft hub locked in place with locking pin for diesel


injection pump -3359-.

• Bolt fitted but not tightened.


• It should just be possible to turn camshaft pulley easily with‐
out axial movement.
• Locking pin -1- in actuating arm loosened one half turn, posi‐
tioned in centre of elongated hole -2-.

2. Toothed belt drive 153


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• Crankshaft is locked in position with crankshaft stop -


T10490-.

• Hub on high-pressure pump locked in place with locking pin


-T10492- -3-.

• Nut fitted but not tightened.


• It should just be possible to turn high-pressure pump pulley
easily without axial movement.
– Turn toothed belt sprocket of camshaft and toothed belt
sprocket of high-pressure pump in their elongated holes
clockwise as far as the stop.

154 Rep. gr.15 - Cylinder head, valve gear


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– Fit toothed belt in sequence described:


1- Crankshaft pulley
2- Tensioning pulley
3- Camshaft toothed belt pulley
4- High-pressure pump toothed belt pulley
5- Coolant pump toothed belt pulley
– Loosen nut -1- for tensioning roller -B-, and remove locking
tool -T10265-.

Note

♦ Metal lug of tensioning roller must remain engaged in cast


recess on cylinder head.
♦ Ignore -arrow-.

Caution

The locking bolt must not lie against upper stop of elongated
hole after toothed belt has been tensioned.

– Check that locking bolt -1- is still located between centre of


elongated hole and lower stop -2- Otherwise, move position

2. Toothed belt drive 155


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of camshaft toothed belt pulley one tooth in clockwise direc‐


tion and fit toothed belt again.

– Using angle driver -T10264- or angle driver 8mm -T10409-,


carefully turn tensioning roller eccentric clockwise -arrow-
until indicator -2- is in middle of gap in base plate.

• Make sure that the nut -1- does not turn at the same time.
– Hold belt tensioner in this position and tighten nut.
– Position counterhold -T10172- with adapters -T10172/11- on
camshaft sprocket as shown in illustration.

– Push counterhold anti-clockwise -arrow-, and maintain ten‐


sion.
– In this position, tighten bolt -1- for camshaft pulley and nut
-2- for high-pressure pump pulley to 20 Nm.

156 Rep. gr.15 - Cylinder head, valve gear


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Note

The high-pressure pump pulley can only be turned to a limited


extent. It is therefore essential to ensure that the toothed belt
pulley has not been turned to the »limit« after tensioning.

– Ensure that marking on high-pressure pump toothed belt


pulley is not in alignment with locking pin. If necessary,
move position of high-pressure pump pulley one tooth in
clockwise direction and fit toothed belt again.

– Remove locking pins -3359-, -T10492- and crankshaft stop


-T10490-, and check valve timing ⇒ page 157 .
Checking valve timing:

Caution

Irreparable engine damage can be caused if the toothed belt


slips.
♦ Only turn crankshaft in engine direction of rotation.

– Turn crankshaft by pulley bolt 2 turns in engine's direction of


rotation until crankshaft is right before “TDC” position.
– Fit crankshaft stop -T10490- on crankshaft sprocket again.

2. Toothed belt drive 157


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– Turn crankshaft in engine direction of rotation until crank‐


shaft stop pin -arrow- engages in sealing flange whilst turn‐
ing.

Caution

Adjustment fault through inexact “TDC” position.


♦ If camshaft has been turned beyond “TDC”, turn cam‐
shaft twice again, stopping it is just before “TDC”. Then
turn further in the same direction and lock crankshaft
with crankshaft stop -T10490-.

• It must be possible to lock the hub of the camshaft in place


with the locking pin for diesel injection pump -3359-.

• It is very difficult to find the locking point of the high-pressure


pump hub again. A minor deviation -arrow-, though, does not
influence engine operation.

• The belt tensioner indicator -2- must be in the middle be‐


tween tabs -1- and -3- of the base plate.

158 Rep. gr.15 - Cylinder head, valve gear


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Note

The indicator -2- must not be offset relative to tab -1- by more
than 6 mm -a- in direction of engine rotation.

If the conditions are fulfilled, continue with the valve timing cor‐
rectly adjusted ⇒ page 160 .
If the conditions are not fulfilled, correct the valve timing ⇒ page
159 .
Correcting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop
-T10490- until pin is clear of bore.
– Turn crankshaft back to slightly before “TDC” by turning it in
the opposite direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation
until camshaft hub can be locked in position.
– After locking, loosen camshaft pulley bolts.
A - If pin of crankshaft stop -T10490- is on left side of bore:

– Turn crankshaft in engine direction of rotation until crank‐


shaft stop pin -arrow- engages in sealing flange whilst turn‐
ing.
– Tighten camshaft pulley bolts to 20 Nm.
B - If pin of crankshaft stop -T10490- is on right side of bore:
– First, turn crankshaft a little in direction opposite to engine's
direction of rotation.
– Turn crankshaft in engine's direction of rotation again until
crankshaft stop pin engages in sealing flange whilst turning.
– Tighten camshaft pulley bolts to 20 Nm.

2. Toothed belt drive 159


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Procedure after adjusting valve timing correctly:


– Remove diesel injection pump locking pin -3359- and crank‐
shaft stop -T10490-.
– Turn crankshaft by pulley bolt 2 turns in engine's direction of
rotation until crankshaft is right before “TDC” position.
– Check valve timing again ⇒ page 157 .

Caution

It is essential that the torque for loosening and tightening


the central bolts on camshaft and high-pressure pump is not
transferred to the respective locking pin. Otherwise the »fol‐
lower« may be damaged even if a counterhold is used.
These defects may not be noticed and may result in damage
to the engine. Therefore, pull out locking pin for loosening
and tightening the central bolt and reinsert the locking after‐
wards if necessary.

– If camshaft hub can now be locked, tighten bolt -1- for cam‐
shaft toothed belt pulley to final torque using counterhold
-T10172- with adapters -T10172/11- ⇒ Item 10 (page 139) .

– Tighten bolts -2- for high-pressure pump toothed belt pulley


to final torque ⇒ page 138 using counterhold -T10051-.
– Check valve timing again ⇒ page 157 .
Installing
Further installation is carried out in the reverse order of remov‐
al; note the following:

Note

♦ Renew seals.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Tighten locking pin -1-.

160 Rep. gr.15 - Cylinder head, valve gear


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Specified torques
♦ ⇒ o2.2 verview - toothed belt”, page 138
♦ ⇒ o2.1 verview - toothed belt cover”, page 138

2.5 Removing toothed belt from camshaft


Special tools and workshop equipment required
♦ Diesel injection pump locking pin -3359-

♦ Counterhold -T10051-

2. Toothed belt drive 161


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♦ Counterhold -T10172- with adapters -T10172/11-

♦ Angle driver -T10264-

♦ Locking tool -T10265-

♦ Locking pin -T10492-

162 Rep. gr.15 - Cylinder head, valve gear


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♦ Crankshaft stop -T10490-

♦ Torque wrench -V.A.G 1410-

♦ Ring spanner -T10024-

Note

The flywheel is equipped with centrifugal weights. The centrifu‐


gal weights generate a »clacking sound« when the engine is
cranked by hand. The »clacking sound« is generated by design
and there is no need to raise a complaint. When the cranking
speed is attained, the noise will disappear.

Removing
– Remove upper part of toothed belt guard ⇒ page 140 .
– Remove vibration damper ⇒ page 69 .

Caution

Risk of destruction due to toothed belt jumping.


♦ Only turn crankshaft in engine direction of rotation.

2. Toothed belt drive 163


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– Turn crankshaft by bolt for toothed belt sprocket until toothed


belt for camshaft is at “TDC”.

Note

The arrow on the camshaft toothed belt pulley faces upwards.

– Lock camshaft hub with diesel injection pump locking pin


-3359-; to do so, insert locking pin into fork on actuating arm
-2- and into hole -1- behind it in cylinder head.

– Loosen locking pin -1- in camshaft sprocket one half turn,


but do not remove.

– Lock crankshaft sprocket in position with crankshaft stop


-T10490-.

• Pins of crankshaft stop -T10490- must engage in threaded


holes of toothed belt sprocket.
• Locking pin of crankshaft stop -T10490- must engage in hole
on sealing flange.

164 Rep. gr.15 - Cylinder head, valve gear


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• The crankshaft stop -T10490- must be flush with the toothed


belt pulley.
– Loosen bolt -arrow- for camshaft pulley.

– To do this, use counterhold -T10172- with adapters -


T10172/11-.
– Lock hub of high-pressure pump in place with locking pin
-T10492- -3-.

– To do this, insert locking pin -T10492- into fork -2- of hub


and into hole -1- behind it in ancillary bracket.
– Turn locking pin -T10492- -B- until straight edge points to
right as shown.

– Apply counter-hold tool -T10051- -A-.


– Loosen nut -arrow- for high-pressure pump pulley by approx.
90°.
– Loosen nut -1- for belt tensioner.

2. Toothed belt drive 165


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– Turn eccentric of tensioning roller anti-clockwise -arrow- us‐


ing angle driver -T10264-, until the tensioning roller can be
locked with locking tool -T10265-.
– Turn belt tensioner eccentric clockwise -arrow- to stop using
special wrench, long reach -T10264-.

– Tighten nut -1- by hand.


– Take toothed belt off camshaft sprocket.
Installing (adjusting valve timing) ⇒ page 152

166 Rep. gr.15 - Cylinder head, valve gear


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3 Valve gear
⇒ o3.1 verview - valve gear”, page 167
⇒ a3.2 xial play of camshaft”, page 169
⇒ a3.3 nd installing camshaft oil seal”, page 170
⇒ h3.4 ydraulic compensation elements”, page 172
⇒ a3.5 nd installing valve stem seals”, page 173

3.1 Assembly overview - valve gear

Caution

Avoid damage to valves and piston crowns after working on


valve gear.
♦ Because hydraulic compensation elements have to set‐
tle, engine must not be started for approx. 30 minutes
after installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to en‐
sure that none of the valves make contact when the
starter is operated.

3. Valve gear 167


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1 - Cap
❑ Renew after removal
❑ Removing: With cam‐
shaft housing installed,
pierce on one side of
sealing cap with an awl
and pry out.
❑ Installing: Drive in
without sealant until
flush using suitable
thrust piece, e.g. carrier
-3390-.
2 - Camshaft seal
❑ Renew after removal ⇒
page 170
3 - Camshaft case
❑ With integrated cam‐
shafts
❑ Specified torque: ⇒
page 169
❑ Removing and instal‐
ling ⇒ page 131
4 - Seal
❑ Renew after removal
5 - Cover
6 - Bolt
❑ 8 Nm
7 - Bolt
❑ Specified torque: ⇒
page 616
8 - Hall sender -G40-
❑ Assembly overview ⇒
page 616
9 - O-ring
❑ Renew after removal
10 - Cylinder head
❑ With dowel pins for camshaft housing

Note

Valve seats must not be reworked


due to the very small tolerances.
Only lapping-in is permitted.

11 - Valve
❑ Do not rework; only grinding-in is permissible
❑ Mark installation position for re-installation.
❑ Checking ⇒ page 183
❑ Valve dimensions ⇒ page 183
❑ Checking valve guides ⇒ page 182
12 - Valve stem seal
❑ Renew after removal ⇒ page 173

168 Rep. gr.15 - Cylinder head, valve gear


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13 - Valve springs
14 - Valve spring plate
15 - Valve cotters
16 - Hydraulic compensation element
❑ Checking ⇒ page 172
❑ Mark installation position for re-installation.
❑ Lubricate contact surfaces before installing.
17 - Roller rocker fingers
❑ Removing and installing ⇒ page 131
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.
18 - Retaining clip
❑ For hydraulic compensation element.

Camshaft housing - specified torque and tightening sequence

– Tighten bolts in stages in the sequence shown.


Stage Bolts Specified torque
1 -1 to 15- Screw in by hand as far as stop
• The camshaft housing must make
contact with the cylinder head
over the entire contact surface.

2 -1 to 15- 10 Nm

3.2 Measuring axial play of camshaft


Special tools and workshop equipment required

3. Valve gear 169


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♦ Universal dial gauge holder -VW 387-

♦ Dial gauge -VAS 6079-

Procedure
– Remove camshaft housing ⇒ page 131 .
– Secure dial gauge -VAS 6079- with universal dial gauge
bracket -VW 387- to camshaft housing as shown in illustra‐
tion.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.05 to 0.15 mm

3.3 Removing and installing camshaft oil


seal
Special tools and workshop equipment required
♦ Puller -T10443-

170 Rep. gr.15 - Cylinder head, valve gear


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♦ Assembly tool -T10493-

Procedure
– Remove toothed belt from camshaft ⇒ page 161 .

Caution

♦ If unscrewed too far, the internal thrust plate of the puller


-T10443- detaches from the thrust screw. In this case,
the pressure plate must be pressed back on to the thrust
bolt.

– Carefully unscrew grub screw -arrow- of puller -T10443- until


a slight resistance is felt.
– Position puller -T10443- such that it is straight, as shown in
illustration, and lock it in place by screwing in grub screw
-A-.

– Screw in thrust bolt -B- until oil seal is extracted.


– Clean contact surface and sealing surface.

3. Valve gear 171


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Note

Sealing lip of oil seal must not be additionally oiled or greased.

– Fit guide sleeve -T10493/1- onto camshaft as shown in illus‐


tration.

– Carefully slide oil seal -1- over guide sleeve onto camshaft.

Note

The guide sleeve remains on the camshaft as a stop while the


oil seal is being pressed in.

– Press oil seal in onto stop using press tool -T10493/2- and
bolt -T10493/3-.

– Install toothed belt (adjust valve timing) ⇒ page 152 .

3.4 Checking hydraulic compensation ele‐


ments

Note

♦ The hydraulic compensation elements cannot be repaired.


♦ Irregular valve noise during starting is normal.

Special tools and workshop equipment required


♦ Feeler gauge

172 Rep. gr.15 - Cylinder head, valve gear


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Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2500 rpm for 2 minutes;
perform road test if necessary.

Note

If the irregular valve noises stop but recur repeatedly during


short journeys, the oil retention valve must be renewed. Oil
retention valve is located in air filter housing ⇒ Item 9 (page
196) :

– If the hydraulic compensation elements are still noisy, find


out which is the defective compensation element as follows:
– Remove cylinder head cover ⇒ page 126 .
– Turn crankshaft by the bolt for the toothed belt wheel until
cam of supporting element to be tested is facing upwards.
– Press roller rocker finger downwards -arrow- to check clear‐
ance between cam and roller rocker finger.

– If a 0.20 mm feeler gauge can be inserted between cam and


roller rocker finger, replace hydraulic compensation element
⇒ page 131 .
Concluding measures
– Install cylinder head cover ⇒ page 126 .

3.5 Removing and installing valve stem


seals
⇒ a3.5.1 nd installing valve stem seals (cylinder head instal‐
led)”, page 173
⇒ a3.5.2 nd installing valve stem seals (cylinder head re‐
moved)”, page 177

3.5.1 Removing and installing valve stem


seals (cylinder head installed)
Special tools and workshop equipment required

3. Valve gear 173


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♦ Valve stem seal puller -3364-

♦ Valve stem seal fitting tool -3365-

♦ Valve spring tool -3362-

Procedure
– Remove camshaft housing ⇒ page 131 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.

174 Rep. gr.15 - Cylinder head, valve gear


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– Remove roller rocker fingers together with hydraulic com‐


pensation elements and place on a clean surface.
– Set piston of respective cylinder to “top dead centre”.

Note

♦ The pistons of cylinders no. 1 and no. 4 are at »TDC« posi‐


tion after the camshaft housing has been removed.
♦ The pistons of cylinders no. 2 and no. 3 are at »bottom
dead centre« position after the camshaft housing has been
removed.
♦ Crank engine via crankshaft half a turn in direction of en‐
gine rotation. The pistons for cylinders no. 1 and no. 4 are
at »bottom dead centre« position.
♦ When cranking the engine, hold and guide the toothed belt
by hand to prevent it from being damaged.

Cylinders 1, 2, and 3:
– Place valve spring tool -3362- on cylinder head and screw
tight. Use bolts from camshaft housing to do this.
– To secure, use M6 bolts with a thread length of 20 mm.
– Position threaded connections in such a way that valve
spring tool -3362- is located above respective valve.
Cylinder 4:
– Place valve spring tool -3362- on cylinder head and screw
tight. Use bolts from camshaft housing to do this.
– Distance between valve spring tool -3362- and cylinder head
must be larger due to restricted space.
– To do this, insert spacer sleeves at threaded connection
points from valve spring tool -3362- on cylinder head.
– Spacer sleeves must be at least 30 mm in length. To secure,
use M6 bolts with a thread length of at least 50 mm.
– Position threaded connections in such a way that valve
spring tool -3362- is located above respective valve.
Continued for all cylinders:

Note

Pressure hose -VW653/3- in the figure is of no relevance.

3. Valve gear 175


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– Align shaft for spindle from valve spring tool -3362- to valve
head of respective valve.
– Engage shaft in side retainers in upper position, as shown.
– Valve spring tool -3362- must be vertically above valve
spring.
– Thrust piece -3362/1- from valve spring tool -3362- must be
flush with valve head.
– Side retainers from valve spring tool -3362- must rest
against cylinder head.
– Compress valve spring with thrust piece -3362/1-.
– Screw spindle down until valve cotters can be removed with
a magnet.
– Ensure when screwing down that thrust piece -3362/1- does
not cant on cylinder head.
– Strike tight valve cotters with a plastic hammer and drift
-VAS 5161/3A-. Remove spring valve tool -3362- to do this.
– After removing valve cotters, measure and note thread
length of spindle for re-installation.
– Pull off valve stem seal using valve stem seal puller -3364-.

– Lightly oil sealing lip of valve stem oil seal and valve stem.
– Carefully push valve stem oil seal on valve stem -A-.

176 Rep. gr.15 - Cylinder head, valve gear


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– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool -3365-.
– Repeat procedure on each valve.
Installing
Assembly is carried out in reverse sequence; note the following:
– Insert valve spring and valve spring plate.
– Align valve spring tool -3362- towards valve.
– Screw thrust piece -3362/1- with spindle down to previously
calculated dimension. Do not screw spindle down too far as
it will not be possible to insert valve cotters properly other‐
wise.
– Insert valve cotters and screw spindle up.
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensa‐
tion elements.
– Install camshaft housing ⇒ page 131 .

3.5.2 Removing and installing valve stem


seals (cylinder head removed)
Special tools and workshop equipment required
♦ Engine and gearbox support -VAS 6095-

♦ Cylinder head tensioning device -VAS 6419-

3. Valve gear 177


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♦ Valve stem seal puller -3364-

♦ Valve stem seal fitting tool -3365-

♦ Valve spring tool -3362-

Procedure
– Remove cylinder head ⇒ page 120 .
– Remove engine lifting eye ⇒ Item 2 (page 114) .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.

178 Rep. gr.15 - Cylinder head, valve gear


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– Remove roller rocker fingers together with hydraulic com‐


pensation elements and place on a clean surface.
– Insert cylinder head clamping device -VAS 6419- into engine
and gearbox support -VAS 6095-.
– Tension cylinder head on cylinder head clamping device as
shown in illustration.

– Connect cylinder head clamping device to compressed air.


– Use lever -arrow- to slide air cushion under combustion
chamber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies
against valve disc.
– Place valve spring tool -3362- on cylinder head and screw
tight. Use bolts from camshaft housing to do this.
– To secure, use M6 bolts with a thread length of 20 mm.
– Position threaded connections in such a way that valve
spring tool -3362- is located above respective valve.
– Align shaft for spindle from valve spring tool -3362- to valve
head of respective valve.

Note

Pressure hose -VW653/3- in the figure is of no relevance.

– Engage shaft in side retainers in upper position, as shown.


– Valve spring tool -3362- must be vertically above valve
spring.
– Thrust piece -3362/1- from valve spring tool -3362- must be
flush with valve head.

3. Valve gear 179


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– Side retainers from valve spring tool -3362- must rest


against cylinder head.
– Compress valve spring with thrust piece -3362/1-.
– Screw spindle down until valve cotters can be removed with
a magnet.
– Ensure when screwing down that thrust piece does not cant
on cylinder head.
– Strike tight valve cotters with a plastic hammer and drift
-VAS 5161/3A-. Remove spring valve tool -3362- to do this.
– After removing valve cotters, measure and note thread
length of spindle for re-installation.
– Pull off valve stem seal using valve stem seal puller -3364-.

– Lightly oil sealing lip of valve stem oil seal and valve stem.
– Carefully push valve stem oil seal on valve stem -A-.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool -3365-.
– Repeat procedure on each valve.
Installing
Assembly is carried out in reverse sequence; note the following:
– Insert valve spring and valve spring plate.
– Align valve spring tool -3362- towards valve.

180 Rep. gr.15 - Cylinder head, valve gear


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– Screw thrust piece -3362/1- with spindle down to previously


calculated dimension. Do not screw spindle down too far as
it will not be possible to insert valve cotters properly other‐
wise.
– Insert valve cotters and screw spindle up.
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensa‐
tion elements.
– Install cylinder head ⇒ page 120 .

3. Valve gear 181


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4 Inlet and exhaust valves


⇒ v4.1 alve guides”, page 182
⇒ v4.2 alves”, page 183
⇒ d4.3 imensions”, page 183

4.1 Checking valve guides


Special tools and workshop equipment required
♦ Universal dial gauge holder -VW 387-

♦ Dial gauge -VAS 6079-

Procedure

Note

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


valve for the measurement.
♦ Due to differing stem diameters, only use an inlet valve in in‐
let valve guide and an exhaust valve in exhaust valve guide.

– Attach dial gauge -VAS 6079- with universal dial gauge hold‐
er -VW 387- to cylinder head.

182 Rep. gr.15 - Cylinder head, valve gear


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– Insert valve into valve guide.


• The end of the valve stem must be flush with the guide.
– Determine rock.
• Wear limit: 1.0 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.

Note

Valve guides cannot be exchanged.

4.2 Checking valves


– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.

4.3 Valve dimensions

Note

Never rework the inlet and exhaust valves. Only lapping-in is


permitted.

Dimension Inlet valve Outlet valve


∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45

4. Inlet and exhaust valves 183


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17 – Lubrication
1 Sump, oil pump
⇒ o1.1 verview - sump/oil pump”, page 184
⇒ o1.2 il:”, page 186
⇒ a1.3 nd installing sump”, page 186
⇒ a1.4 nd installing oil pump”, page 191
⇒ a1.5 nd installing oil level and oil temperature senderG266”,
page 192

1.1 Assembly overview - sump/oil pump

Note

♦ Metal shavings or a large quantity of small metal particles found during engine repair could indicate that
the crankshaft bearings or conrod bearings are damaged. To avoid any secondary damage, carry out the
following work following the repair: carefully clean oil channels and renew oil spray jets, engine oil cooler
and oil filter.
♦ Oil spray jet and pressure relief valve ⇒ page 105 .

184 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bolt
❑ Self-locking
❑ Renew after removal
❑ 8 Nm
2 - Oil level and oil tempera‐
ture sender -G266-
❑ Removing and instal‐
ling ⇒ page 192
3 - Seal
❑ Renew after removal
4 - Oil drain plug
❑ 30 Nm
5 - Seal
❑ Renew after removal
6 - Bolt
❑ Specified torque and
tightening sequence: ⇒
page 186
7 - Sump
❑ Removing and instal‐
ling ⇒ page 186
8 - O-ring
❑ Renew after removal
9 - Bolt
❑ Renew after removal
Different types of bolted con‐
nections:
♦ Torx socket head bolt:
12 Nm +180°
♦ Hexagon bolt:
10 Nm +180°
10 - Oil pump
❑ With vacuum pump
❑ Removing and installing ⇒ page 191
11 - Dowel sleeve
12 - Toothed belt
❑ Removing and installing
♦ ⇒ a1.4 nd installing oil pump”, page 191
♦ ⇒ a1.8 nd installing sealing flange on pulley end”, page 74
13 - Seal
❑ Renew after removal
14 - Dowel sleeve
15 - Cylinder block
16 - O-ring
❑ Renew after removal
17 - Valve for oil pressure control -N428-
❑ Removing and installing ⇒ page 205

1. Sump, oil pump 185


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

18 - Bolt
❑ 8 Nm
19 - Bolt
❑ 8 Nm
20 - Dipstick guide tube
21 - Bolt
❑ 8 Nm
22 - O-ring
❑ Renew after removal
23 - Bolt
❑ 8 Nm +90°
24 - Baffle plate
25 - Oil intake tube

Sump - specified torque and tightening sequence

– Tighten bolts in stages as follows:


Stage Bolts Specified torque
1 -1 to 20- Tighten to 5 Nm in diagonal se‐
quence, working from centre out‐
wards
2 -Arrows- 40 Nm
3 -1 to 20- Tighten to 13 Nm in diagonal se‐
quence, working from centre out‐
wards

1.2 Engine oil:


Capacities and oil specifications
♦ ⇒ Maintenance; Booklet ; Engine oil: capacities and specifi‐
cations
Changing engine oil
♦ ⇒ Maintenance; Booklet ; Engine oil: draining, renewing oil
filter and replenishing engine oil
Checking oil level
♦ ⇒ Maintenance; Booklet ; Engine oil level: checking

1.3 Removing and installing sump


Special tools and workshop equipment required

186 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ T-bar and socket, 10 mm -3185-

♦ Hexagon bit, long reach -T10058-

♦ Applicator gun -VAS 6966-

♦ Hand drill with plastic brush


♦ Safety glasses
♦ Sealant ⇒ Electronic Parts Catalogue
♦ Cleaning solution -D 291 091 A1-
Removing

1. Sump, oil pump 187


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• Engine oil drained ⇒ Maintenance; Booklet .


– Disconnect electrical connector -arrow- on oil level and oil
temperature sender -G266-.
– Release clips -arrows- and detach noise insulation -1- for
sump.

– Unscrew bolts -arrows- of sump to gearbox connection.

Note

The sump has recesses -arrows- in the centre near the gear‐
box.

♦ The recesses allow access to the two centre bolts -A- be‐
tween the sump and the gearbox.
♦ Loosen bolts -A- using T-bar and socket, WAF 10 -3185-,
then unscrew them using Allen key, long reach -T10058-.

– Loosen bolts -1 to 20- in diagonal sequence, and unscrew


them.
– Release sump carefully from adhesive.

188 Rep. gr.17 - Lubrication


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Installing

Caution

Danger of soiling lubrication system and bearings.


♦ Cover open parts of engine.

WARNING

Wear eye protection and protective gloves when working with


sealant and grease remover.

– Remove sealant residue on cylinder block and sump using


commercially available, chemical sealant remover.
– Remove sealant residue from sump using rotating plastic
brush.

Note

The cleaning solution -D 291 091 A1- is used to activate the


surface before the sealant is applied and is essential for the
proper functionality of the sealing bond.

– Clean all sealing surfaces with cleaning solution -D 291 091


A1-.
– Clean sealing surface on pulley end -arrow- with extra thor‐
oughness.

– Observe the expiry date of the sealant.

1. Sump, oil pump 189


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– Cut off nozzle on tube at front marking (diameter of nozzle:


approx. 2 to 3 mm).
– If necessary, use applicator gun -VAS 6966- to apply seal‐
ant.

Caution

Danger of blocking lubrication system with excess sealant.


♦ Do not apply sealant bead thicker than specified.

Note

♦ The lower surface of the sealing flange on belt pulley end is


offset by approx. 1 mm relative to the lower cylinder block
surface after the old silicone gasket has been removed.
♦ The offset must be compensated by applying sealant to the
relevant area of the sealing surface of the top section of the
sump.

– If necessary, use applicator gun -VAS 6966- to apply seal‐


ant.
– Apply bead of sealant onto clean sealing surface of sump as
illustrated.

• In area of sealing surface of sealing flange on belt pulley


end: 3 … 4 mm.
• In area of sealing surfaces between cylinder block and seal‐
ing flange on gearbox end: 2 to 3 mm.
• The sealant bead in the area of the sealing flange on belt
pulley end must be able to substitute the no longer existent
silicone gasket in terms of height and width.
• The top section of the sump must be installed within 5 mi‐
nutes of the sealant being applied.

190 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ When installing sump with engine removed from vehicle,


ensure that sump is flush with cylinder block at flywheel end.
♦ Allow sealant to dry for approx. 30 minutes after installing
sump. Only then fill with engine oil.

– Insert baffle plate.


– Position oil sump and tighten bolts ⇒ page 186 .
• The sump must be flush with the gearbox flange at the inter‐
mediate plate.
– Replenish engine oil, and check oil level ⇒ Maintenance;
Booklet .
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

1.4 Removing and installing oil pump


Removing

– Remove sump ⇒ page 186 .

Caution

Do not kink or twist toothed belt or damage it on sharp


edges.

– Unscrew bolts -arrows- and remove oil pump -1-.

Caution

The bolt on the pump gear must not be loosened.

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

1. Sump, oil pump 191


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Note

♦ Renew seal after each removal.


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

– Insert dowel sleeves if oil pump has no dowel sleeves


-arrows-.

– Install sump ⇒ page 186 .


Specified torque
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner

1.5 Removing and installing oil level and


oil temperature sender -G266-
Removing

• Engine oil drained ⇒ Maintenance; Booklet .


– Disconnect electrical connector -arrow- on oil level and oil
temperature sender -G266-.
– Release fasteners -arrows- and detach noise insulation -1-
for sump.

192 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -1- and remove oil level and oil temperature
sender -G266- -item 4-.

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

Note

Renew seal -2- and self-locking bolts -1-.

– Replenish engine oil, and check oil level ⇒ Maintenance;


Booklet .
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 184

1. Sump, oil pump 193


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Engine oil cooler

Note

The engine oil cooler must not be separated from the oil filter
housing. In the event of defects, the engine oil cooler must be
renewed together with the oil filter housing ⇒ page 201 .

194 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Oil filter, oil pressure switch


⇒ o3.1 verview - oil filter housing, oil pressure switch”, page 195
⇒ a3.2 nd installing oil pressure switchF1”, page 197
⇒ a3.3 nd installing oil pressure switch for reduced oil pressur‐
eF378”, page 199
⇒ o3.4 il pressure”, page 201
⇒ a3.5 nd installing oil filter housing”, page 201
⇒ a3.6 nd installing oil pressure regulating valveN428”, page
205

3.1 Assembly overview - oil filter housing, oil pressure switch

3. Oil filter, oil pressure switch 195


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1 - Oil drain plug


❑ 5 Nm
2 - O-ring
❑ Renew after removal
3 - Cap
❑ 25 Nm
4 - O-ring
❑ Renew after removal
❑ Moisten with engine oil
5 - Oil filter element
❑ Observe notes ⇒ page
184
❑ Removing and instal‐
ling ⇒ Maintenance;
Booklet
6 - Seal
❑ Renew after removal
7 - Oil pressure switch -F1-
❑ For allocation, refer
to ⇒ Electronic Parts
Catalogue
❑ Switching pressure ⇒
page 197
❑ Check in Guided
fault finding ⇒ Ve‐
hicle diagnostic tester
❑ Removing and instal‐
ling ⇒ page 197
❑ 20 Nm
8 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 197
9 - Oil filter housing with engine oil cooler
❑ Do not separate oil filter housing and engine oil cooler.
❑ Removing and installing ⇒ page 201
10 - Bolt
❑ Renew after removal
❑ Specified torque and tightening sequence: ⇒ page 197
11 - Seal
❑ Renew after removal
12 - Seal
❑ Renew after removal
13 - Oil pressure switch for reduced oil pressure -F378-
❑ For allocation, refer to ⇒ Electronic Parts Catalogue
❑ Switching pressure ⇒ page 197
❑ Check in Guided fault finding ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ page 199
❑ 20 Nm
14 - O-ring

196 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Renew after removal

Oil pressure switch, colour coding and switching pressure


Colour Switching pressure
coding
blue 2.15 … 2.95 bar
grey 2.0 … 2.7 bar
brown 0.55 … 0.85 bar
green 0.3 … 0.6 bar
Oil filter housing - specified torque and sequence

Note

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

– First tighten upper left and lower right bolts.


– Tighten bolts in stages in the sequence shown.
Stage Bolts Specified torque/turning further angle
1 -1 to 5- 20 Nm
2 -1 to 5- Turn 90° further

3.2 Removing and installing oil pressure


switch -F1-
Special tools and workshop equipment required
♦ Socket 24 mm -T40284-

3. Oil filter, oil pressure switch 197


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♦ T-bar and socket, 24 mm -T40175-

♦ Torque wrench -V.A.G 1331-

♦ Ratchet wrench -V.A.G 1331/1-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and pull off connector -arrow-.

198 Rep. gr.17 - Lubrication


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– Place a cloth underneath to catch escaping engine oil.


– Unscrew oil pressure switch -F1- using socket 24 mm -
T40284- or T-bar and socket 24 mm -T40175-.
Installing
Install in reverse order of removal. While doing so, observe the
following:
– Renew drain plug seal after removing ⇒ Item 7 (page 196) .
For allocation, refer to ⇒ Electronic Parts Catalogue
– Cut old oil seal open to remove it.
– Check oil level ⇒ Maintenance; Booklet .
Specified torques
♦ ⇒ o3.1 verview - oil filter housing, oil pressure switch”, page
195

3.3 Removing and installing oil pressure


switch for reduced oil pressure -F378-
Special tools and workshop equipment required
♦ Socket 24 mm -T40284-

♦ T-bar and socket, 24 mm -T40175-

3. Oil filter, oil pressure switch 199


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♦ Torque wrench -V.A.G 1331-

♦ Ratchet wrench -V.A.G 1331/1-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove engine cover panel ⇒ page 61 .
– If necessary, remove air duct and air filter housing ⇒ page
443 .
– Release and pull off connector -arrow-.

Note

Place a cloth underneath to catch escaping engine oil.

– Unscrew oil pressure switch for reduced oil pressure -F378-


using socket 24 mm -T40284- or T-bar and socket, 24 mm
-T40175-.

200 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Renew drain plug seal after removing ⇒ Item 13 (page 196) .
For allocation, refer to ⇒ Electronic Parts Catalogue
– Cut off seal to replace.
– Check oil level ⇒ Maintenance; Booklet .
Specified torques
♦ ⇒ o3.1 verview - oil filter housing, oil pressure switch”, page
195
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o5.1 verview – intake manifold”, page 447

3.4 Checking oil pressure

Note

The speed limiter for protecting the clutch does not allow for
testing all stages of oil pressure control while the vehicle is
stationary. For this reason, oil pressure must be checked using
the vehicle diagnostic tester.

– Connect vehicle diagnostic tester.


– Follow the following path in order to perform the oil pressure
test:
Diagnosis-compatible systems
0001 - Repair groups
17 - Lubrication
Checking oil pressure

3.5 Removing and installing oil filter hous‐


ing
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove air filter housing ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

3. Oil filter, oil pressure switch 201


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Drain coolant ⇒ page 213 .


– Remove coolant pipe (top front) ⇒ page 298 .
– Removing and installing front coolant pipes ⇒ page 299 .
– Remove front coolant connection ⇒ page 301 .
– Remove left coolant pipes ⇒ page 308 .
– Remove thermostat ⇒ page 278 .
– Release hose clips -arrows-.

– Pull coolant hose -2- off thermostat housing -1-.


– Pull coolant hose -3- off oil filter housing -4-.
– Remove charge air cooling pump -V188- together with
bracket, and push it to one side ⇒ page 274 .
– Release and pull off connector -1- on high-pressure pump.

– Unlock and pull connector -2- off coolant temperature sender


-G62-.

202 Rep. gr.17 - Lubrication


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– Unlock and pull connector -2- off coolant temperature send‐


er.

– Release and pull off connector -1- on valve for oil pressure
control -N428-.

– Release and pull off connector -arrow- on oil pressure switch


-F1-.

3. Oil filter, oil pressure switch 203


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– Separate electrical connector -arrow- on oil pressure switch


for reduced oil pressure -F378-.

– Lay wiring harness to one side.


– Place a cloth underneath to catch escaping engine oil.

– Unscrew bolts in the sequence -5 to 1- and detach oil filter


housing together with engine oil cooler.
Installing
Install in reverse order of removal, observing the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Renew seal and O-ring after removal.


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ Fig. ““Connecting coolant hose with plug-in connector”“,
page 324 .
♦ ⇒ o3.1 verview - oil filter housing, oil pressure switch”, page
195
♦ ⇒ o2.2 verview - electric coolant pump”, page 266
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ o3.1 verview - coolant pipes”, page 294

204 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.6 Removing and installing oil pressure


regulating valve -N428-
Removing
Vehicles with air conditioner:

– Remove poly V-belt ⇒ page 67 .


– Separate connector -1- on air conditioning compressor regu‐
lating valve -N280-.

Caution

Danger of damage to air conditioner compressor, refrigerant


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

– Unscrew bolts -arrows-.

WARNING

Danger of injury due to coolant.


♦ Do not open the air conditioner refrigerant circuit.

– Detach air conditioner compressor from bracket (refrigerant


hoses remain connected) and tie up to right side.
Continued for all vehicles:

– Disconnect electrical connector -1-.

3. Oil filter, oil pressure switch 205


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Note

Place a cloth underneath to catch escaping engine oil.

– Unscrew bolt -2- and remove valve for oil pressure control
-N428-.
Installing
Install in reverse order of removal, observing the following:

Note

Renew O-ring after each removal.

– Install poly V-belt ⇒ page 67 .


– Check oil level ⇒ Maintenance; Booklet .
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor

206 Rep. gr.17 - Lubrication


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

19 – Cooling
1 Cooling system/coolant
⇒ d1.1 iagram - coolant hoses”, page 207
⇒ c1.2 ooling system for leaks”, page 209
⇒ c1.3 oolant”, page 213
⇒ w1.4 ith coolant”, page 215
⇒ f1.5 illing quality of cooling system”, page 235
⇒ c1.6 ooling system”, page 237

1.1 Connection diagram - coolant hoses

Note

♦ Red = large coolant circuit.


♦ Brown = small coolant circuit.
♦ Green = charge air cooler coolant circuit.
♦ Blue = heater circuit.
♦ The arrows point in the direction of coolant flow.

1. Cooling system/coolant 207


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Coolant expansion tank


❑ With filler cap for cool‐
ant expansion tank
❑ Check pressure relief
valve ⇒ page 212
2 - Cylinder head/cylinder
block
3 - Auxiliary pump for heating
-V488-
❑ Assembly overview ⇒
page 266
❑ Removing and instal‐
ling ⇒ page 271
4 - Injector for reducing agent
-N474-
❑ Assembly overview ⇒
page 566
❑ Removing and instal‐
ling ⇒ page 559
5 - Heat exchanger for heater
❑ ⇒ Heating, air condi‐
tioning; Rep. gr. 80;
Overview of fitting loca‐
tions - heating
6 - Emission control module
❑ Assembly overview ⇒
page 516
❑ Removing and instal‐
ling ⇒ page 523
7 - Exhaust gas recirculation
cooler
❑ Assembly overview ⇒
page 598
❑ Removing and installing ⇒ page 601
❑ Check for leaks ⇒ page 612
8 - Coupling point
9 - Turbocharger
❑ Assembly overview ⇒ page 341
❑ Removing and installing ⇒ page 354
10 - Gear oil cooler
❑ ⇒ Rep. gr. 34; Gear oil circuit; Removing and installing gear oil cooler
11 - Coolant connection
❑ Fitting location ⇒ Item 6 (page 114)
12 - Thermostat
❑ Assembly overview ⇒ page 262
❑ Removing and installing ⇒ page 278
13 - Auxiliary radiator
❑ Not necessarily installed
❑ Assembly overview ⇒ page 325
❑ Removing and installing ⇒ page 337
14 - Engine oil cooler

208 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Assembly overview ⇒ page 195
❑ Removing and installing ⇒ page 197
15 - Radiator for engine coolant
❑ Assembly overview ⇒ page 323
❑ Removing and installing ⇒ page 327
16 - Exhaust gas recirculation valve 1 -GX5-
❑ With exhaust gas recirculation potentiometer -G212-
❑ With exhaust gas recirculation control motor -V338-
❑ Assembly overview ⇒ page 600
❑ Removing and installing ⇒ page 607
17 - Charge air cooling pump -V188-
❑ Assembly overview ⇒ page 266
❑ Removing and installing ⇒ page 271
18 - Throttle valve module -J338-
❑ Assembly overview ⇒ page 447
❑ Removing and installing ⇒ page 456
19 - Radiator for charge air cooling circuit
❑ Assembly overview ⇒ page 323
❑ Removing and installing ⇒ page 330
20 - Actuator for engine temperature regulation -N493-
❑ Assembly overview ⇒ page 269
❑ Removing and installing ⇒ page 287
21 - Auxiliary heater
❑ ⇒ Auxiliary heater, supplementary heater; Rep. gr. 82; Auxiliary heater, supplementary heater; Over‐
view of fitting locations - auxiliary heater, supplementary heater
22 - Coolant pump
❑ Assembly overview ⇒ page 262
❑ Removing and installing ⇒ page 277
23 - Intake manifold with charge air cooler
❑ Assembly overview ⇒ page 447
❑ Removing and installing ⇒ page 450
❑ Check for leaks ⇒ page 389

1.2 Checking cooling system for leaks


Special tools and workshop equipment required
♦ Cooling system tester -V.A.G 1274 B-

1. Cooling system/coolant 209


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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

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

Note

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


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

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

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


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

210 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Observe pressure on pressure gauge of cooling system test‐


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

• Engine at operating temperature.


Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.

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


– Fit cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/8- to coolant expansion tank.

1. Cooling system/coolant 211


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Build up pressure of approx. 1.5 bar using hand pump of


cooling system tester.
• The pressure must not drop by more than 0.2 bar within
10 minutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.

Note

♦ The pressure drop of 0.2 bar within 10 minutes depends


on the how far the coolant can cool down. The colder the
engine, the lower the pressure drop. If necessary, repeat the
check while the engine is cold.
♦ If the coolant level in the coolant expansion tank has drop‐
ped more than 30 mm despite there being no external signs
of leaks, this is an indication of an air bubble in the cooling
system. The filling quality must be checked in this instance ⇒
page 235 .

Check pressure relief valve in cap.

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


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

212 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Renew filler cap, if pressure relief valve does not open as


described.

1.3 Draining coolant


Special tools and workshop equipment required
♦ Drip tray for workshop hoist -VAS 6208-

♦ Hose clamp pliers -VAS 6340-


♦ Safety glasses
♦ Safety gloves
Draining

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
carefully to release pressure.

– Open cap -5- on coolant expansion tank.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Place drip tray for workshop hoist -VAS 6208- underneath.

1. Cooling system/coolant 213


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Lift retaining clip -1-, and remove coolant hose from radiator.
– Drain coolant.
– Lift retaining clip -2-, and disconnect coolant hose from wa‐
ter radiator for charge air cooler.
– Drain coolant.
– Release hose clip -arrow-, and remove coolant hose at bot‐
tom to auxiliary pump for heating -V488-.

– If necessary, open hose clip at transition to coolant pipe and


pull off coolant hose.
– Drain coolant.
– Open lower clamp -arrow-.

– Pull off coolant hose -3- on charge air cooling pump -V188-
-1-.
– Drain coolant.
– If fitted, pull off lower coolant hose -3- leading to auxiliary
radiator -1-.

214 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– To do this, release retaining clip -arrow-.

1.4 Filling with coolant


⇒ w1.4.1 ith coolant without electric vacuum pump”, page 215
⇒ c1.4.2 oolant with electric vacuum pumpVAS 6096/2”, page
223

1.4.1 Filling with coolant without electric vac‐


uum pump
Prerequisites:
• Coolant has been drained ⇒ page 213 .

Note

♦ If the electric vacuum pump -VAS 6096/2- is available, use it


to fill the cooling system ⇒ page 223 .
♦ A higher vacuum is achieved in the cooling system using the
electric vacuum pump -VAS 6096/2-. This higher vacuum
means that there is less air in the cooling system after filling.
Consequently, a »shorter« bleeding routine with ⇒ Vehicle
diagnostic tester is then necessary.

Special tools and workshop equipment required


♦ Refractometer -T10007A-

1. Cooling system/coolant 215


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Drip tray for workshop hoist -VAS 6208-

♦ Hose clamp pliers -VAS 6340-

♦ Cooling system charge unit -VAS 6096-

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

♦ Safety glasses
♦ Safety gloves
Filling
After renewing the components:

216 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Cylinder head
♦ Heat exchanger for heater
♦ Radiator for engine coolant
♦ Radiator for charge air cooling circuit
♦ Intake manifold with charge air cooler
If replenishing is not sufficient, flush cooling system ⇒ page 237

Caution

Risk of damage to the engine due to insufficiently filled/bled


cooling system.
♦ Always bleed cooling system with ⇒ Vehicle diagnostic
tester after it has been filled.

Procedure
– Re-connect all coolant hoses that were pulled off.

1. Cooling system/coolant 217


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Coolant specifications

218 Rep. gr.19 - Cooling


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Note

♦ The water used for mixing has a major influence on the ef‐
fectiveness 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 specified by Volkswagen. Distilled water satisfies all
requirements. Therefore, only ever use distilled water when
mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives as per ⇒ Electronic parts cata‐
logue (ETKA). Other coolant additives may reduce corrosion
protection substantially. The resulting damage could lead
to loss of coolant and subsequent severe damage to the
engine.
♦ Mixed in the proper proportions, coolant inhibits frost and
corrosion damage as well as scaling. Additives also raise the
boiling point of the coolant. Therefore, the cooling system
must be filled all year round with coolant additive.
♦ Because of its high boiling point, coolant improves engine
reliability under heavy loads, particularly in countries with
tropical climates.
♦ The refractometer -T10007A- or refractometer -T10007B-
must be used to determine the current anti-freeze value.

♦ The scale -1- of the refractometer is calibrated for the cool‐


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

1. Cooling system/coolant 219


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ti-freeze protection must be guaranteed down to at least


-25°C.
♦ The temperature reading on the refractometer corresponds
to the »ice flocculation point«. Flakes of ice may start form‐
ing in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.

Coolant mixture ratio


• Coolant (40%) and distilled water (60%) for frost protection
to -25°C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant: ⇒ Electronic Parts Catalogue.
– Fill reservoir of -VAS 6096- with at least 8 litres of pre-mixed
coolant in correct mixture ratio.

– Screw adapter for cooling system tester -V.A.G 1274/8- onto


coolant expansion tank.
– Fit cooling system charge unit -VAS 6096- onto adapter for
cooling system tester -V.A.G 1274/8-.
– Feed vent hose -2- into a small container -3-.

Note

Exhaust air takes a slight quantity of coolant along with it; this
should be collected.

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


flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.

220 Rep. gr.19 - Cooling


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• The suction-jet pump reduces pressure in the cooling sys‐


tem to below atmospheric pressure.
• The needle on the gauge should move into the green zone.
– In addition, briefly open valve -A- (turn lever in direction of
flow to do this) so that hose on -VAS 6096- reservoir fills
with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• The suction-jet pump will continue generating a vacuum in
the cooling system. The needle on the gauge must remain in
the green zone.
– Close valve -B-.
• The needle on the gauge must stay in the green zone. The
low pressure in the cooling system is then sufficient for sub‐
sequent filling.

Note

♦ If the needle does not reach the green zone, repeat the
process.
♦ If the vacuum drops, check the cooling system for leaks.

– Pull off compressed air hose.


– Open valve -A-.
• The partial vacuum in cooling system causes coolant to be
extracted from -VAS 6096- reservoir and coolant system to
be filled.
– Remove cooling system charge unit -VAS 6096- from cool‐
ant expansion tank.
Bleeding cooling system:
– Fill coolant up to “max.” mark. Leave cap of coolant expan‐
sion tank off.

1. Cooling system/coolant 221


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– Unscrew bleeder screw -arrow- from thermostat -1- on water


radiator for charge air cooling circuit approx. 1 turn until
coolant escapes without bubbles.

– Fill coolant to approx. 20 mm above weld seam -arrow- and


close coolant expansion tank.

– On vehicles with auxiliary heater, switch on auxiliary heater


for about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in button should not light up.
– Connect
vehicle diagnostic tester
.
– Switch on ignition, and select following menu option on
⇒ Vehicle diagnostic tester:
Diagnosis-compatible systems
0001 - Engine electronics - diesel (2.0l)

222 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

0001 - Engine electronics, functions


0001 - Fill/bleed cooling system
– Follow instructions shown on vehicle diagnostic tester.
– Allow engine to cool down.
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
Checking coolant level after repair work
• When engine is at operating temperature, coolant level must
be about 20 mm above »weld seam« -arrow-.

• When the engine is cold, the coolant level must be approx.


5 mm above the max. mark.

– Replenish coolant if necessary.

Note

This excessive amount of coolant is necessary since the cool‐


ant level will decrease due to bleeding process.

1.4.2 Filling coolant with electric vacuum


pump -VAS 6096/2-
Prerequisites:
• Coolant has been drained ⇒ page 213 .
• Electric vacuum pump is OK ⇒ e1.4.3 lectric vacuum pump‐
VAS 6096/2”, page 234 .

1. Cooling system/coolant 223


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

A higher vacuum is achieved in the cooling system using


the electric vacuum pump -VAS 6096/2-. This higher vacuum
means that there is less air in the cooling system after filling.
Consequently, a »shorter« bleeding routine with ⇒ Vehicle diag‐
nostic tester is then necessary.

Special tools and workshop equipment required


♦ Cooling system charge unit -VAS 6096-

♦ Electric vacuum pump -VAS 6096/2-


♦ Coolant reservoir -VAS 6968-
♦ Test adapter -VAS 691 005/5-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Refractometer -T10007B-

224 Rep. gr.19 - Cooling


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♦ Hose clamps to 25 mm -3094-

After renewing the components:


♦ Cylinder head
♦ Heat exchanger for heater
♦ Radiator for engine coolant
♦ Radiator for charge air cooling circuit
♦ Intake manifold with charge air cooler
If replenishing is not sufficient, flush cooling system ⇒ page 237

Caution

Risk of damage to the engine due to insufficiently filled/bled


cooling system.
♦ Always bleed cooling system with ⇒ Vehicle diagnostic
tester after it has been filled.

– Re-connect all coolant hoses that were pulled off.

1. Cooling system/coolant 225


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Coolant specifications

226 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ The water used for mixing has a major influence on the ef‐
fectiveness 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 specified by Volkswagen. Distilled water satisfies all
requirements. Therefore, only ever use distilled water when
mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives as per ⇒ Electronic parts cata‐
logue (ETKA). Other coolant additives may reduce corrosion
protection substantially. The resulting damage could lead
to loss of coolant and subsequent severe damage to the
engine.
♦ Mixed in the proper proportions, coolant inhibits frost and
corrosion damage as well as scaling. Additives also raise the
boiling point of the coolant. Therefore, the cooling system
must be filled all year round with coolant additive.
♦ Because of its high boiling point, coolant improves engine
reliability under heavy loads, particularly in countries with
tropical climates.
♦ The refractometer -T10007A- or refractometer -T10007B-
must be used to determine the current anti-freeze value.

♦ The scale -1- of the refractometer is calibrated for the cool‐


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

1. Cooling system/coolant 227


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

ti-freeze protection must be guaranteed down to at least


-25°C.
♦ The temperature reading on the refractometer corresponds
to the »ice flocculation point«. Flakes of ice may start form‐
ing in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.

Coolant mixture ratio


• Coolant (40%) and distilled water (60%) for frost protection
to -25°C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant: ⇒ Electronic Parts Catalogue.
– Screw test adapter -VAS 691 005/5- -2- onto coolant expan‐
sion tank -1-.

– Perform electric vacuum pump -VAS 6096/2- check ⇒ page


234 .
– Set-up coolant bowser VAS 6968 so that it is higher than the
coolant expansion tank -arrows- and fill at least 10 litres of
premixed coolant in the correct ratio.

– Connect cooling system charge unit -VAS 6096- to coolant


reservoir -VAS 6968- as shown.

228 Rep. gr.19 - Cooling


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• Wait before connecting cooling system charge unit -VAS


6096- to test adapter -VAS 691 005/5-. The filler hose must
be bled first.
– Bleed hose -2-. This is done by briefly opening valve on
coolant reservoir and valves -A- and -B- until hose -2- is
filled with coolant.
– Close valves -A- and -B- (turn lever transverse to direction of
flow to do this).
– Open filler cap on expansion tank.
– Fit cooling system charge unit -1- on test adapter -2-.

– Fit hose -1- of electric vacuum pump -VAS 6096/2- on plug-


in connector -B- of cooling system charge unit.

– Connect electric vacuum pump -VAS 6096/2- to vehicle bat‐


tery and switch on. Open valve -B-.
– Ensure, when generating vacuum, that water separator -1- in
vacuum pump is not filled with coolant.

1. Cooling system/coolant 229


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Caution

Risk of damage to electric vacuum pump from coolant being


drawn in.
♦ Ensure that electric vacuum pump does not draw in
coolant. If necessary, interrupt procedure and purge
coolant expansion tank ⇒ page 230 .

– Generate vacuum with electric vacuum pump until indicator


on pressure gauge -arrow- is significantly below green area.

– Close valve -B- and switch off electric vacuum pump -VAS
6096/2-.
– Observe pressure gauge. Needle of pressure gauge must
not move.
– If conditions are met, cooling system can be filled ⇒ page
231 .
If water separator in electric vacuum pump fills with coolant,
coolant expansion tank must be purged:

– Close shut-off valve -B- and switch off electric vacuum


pump.
– Seal supply hose -2- and return hose -1- of coolant expan‐
sion tank with hose clamps up to 25 mm -3094-.
– Pull off plug-in connector -arrow- and open shut-off tap -B-
so that coolant expansion tank is vented.

230 Rep. gr.19 - Cooling


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– Remove cooling system charge unit -VAS 6096- and test


adapter -VAS 691 005/5-.
– Extract coolant from coolant expansion tank.
– Re-assembly cooling system charge unit and test adapter
and remove hose clips.
– Switch on electric vacuum pump and generate vacuum
again.
Fill cooling system:

Prerequisites:
• Needle on pressure gauge -arrow- must clearly be below
green area.
– »Slowly« open shut-off tap -A- to prevent coolant from foam‐
ing.

• Vacuum in the cooling system causes coolant to be extrac‐


ted from the reservoir VAS 6968 and fill the cooling system.
– Close shut-off tap -A- after filling.

1. Cooling system/coolant 231


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– Remove electric vacuum pump -VAS 6096/2-, cooling sys‐


tem charge unit -VAS 6096- and test adapter -VAS 691
005/5- from coolant expansion tank.
Bleeding cooling system:
– Fill coolant up to “max.” mark. Leave cap of coolant expan‐
sion tank off.

– Unscrew bleeder screw -arrow- from thermostat -1- on water


radiator for charge air cooling circuit approx. 1 turn until
coolant escapes without bubbles.

– Fill coolant to approx. 20 mm above weld seam -arrow- and


close coolant expansion tank.

– On vehicles with auxiliary heater, switch on auxiliary heater


for about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in button should not light up.
– Connect

232 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

vehicle diagnostic tester


.
– Switch on ignition, and select following menu option on
⇒ Vehicle diagnostic tester:
♦ Diagnosis capable systems Diagnosis capable systems
♦ 0001 - Engine electronics - diesel (2.0l)
♦ 0001 - Engine electronics, functions
♦ 0001 - Fill/bleed cooling system

Note

Answer the question “Was the cooling system filled with the
aid of electric vacuum pump VAS 6096/2?” with “yes” so that
the »shorter« bleeding routine can be initiated.

– Follow instructions shown on vehicle diagnostic tester.


– Allow engine to cool down.
– Install noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
Checking coolant level after repair work
• When engine is at operating temperature, coolant level must
be about 20 mm above »weld seam« -arrow-.

• When the engine is cold, the coolant level must be approx.


5 mm above the max. mark.

– Replenish coolant if necessary.

1. Cooling system/coolant 233


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Note

This excessive amount of coolant is necessary since the cool‐


ant level will decrease due to bleeding process.

1.4.3 Checking electric vacuum pump -VAS


6096/2-

Note

In order to ensure proper filling of the cooling system, a check


(self-test) must be carried out before using the cooling system
charge unit -VAS 6096- or the electric vacuum pump -VAS
6096/2-.

– Fit hose -1- of electric vacuum pump -VAS 6096/2- on plug-


in connector -B- of cooling system charge unit -VAS 6096-.

– Connect electric vacuum pump -VAS 6096/2- to vehicle bat‐


tery and switch on.
– Shut valve -A-, and open valve -B-.
– The needle of the pressure gauge -arrow- must move dis‐
tinctly below the green area.

– Close valve -B-, and switch off electric vacuum pump -VAS
6096/2-.
– Observe negative pressure on pressure gauge for 10 sec‐
onds. Needle must not move.

234 Rep. gr.19 - Cooling


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If insufficient negative pressure builds up, or if pressure rises


again:
Cooling system charge unit -VAS 6096-, pressure gauge or
electric vacuum pump -VAS 6096/2- is leaking or defective and
must not be used.

1.5 Checking filling quality of cooling sys‐


tem

Note

It is necessary to make sure that there is no air in the cooling


system. If there is any air in the cooling system, the coolant
level will drop far below the permissible level in the course of
time. Overheating of the motor is also possible.

Special tools and workshop equipment required


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

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

Condition
• Ignition off
• Coolant temperature between 40°C and 60°C
– Open filler cap -arrow- for coolant expansion tank.

1. Cooling system/coolant 235


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– Check coolant level, which must be approx. 5 mm -arrow-


above the max. mark. If necessary, top up with coolant.

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


V.A.G 1274/8- to coolant expansion tank.

– Build up pressure of 1.5 bar using hand pump of cooling


system tester.
– Observe coolant level in expansion tank.
If the coolant level in the coolant expansion tank has dropped
more than 30 mm, this is an indication of an air bubble in the

236 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

cooling system: The bleeding process with the vehicle diagnos‐


tic tester must be carried out.

♦ Guided Functions
♦ Engine electronics
♦ Charge/bleed cooling system
– Once bleeding has been carried out, top up coolant to ap‐
prox. 5 mm -arrow- above max. marking.

– Repeat filling quality check.


If the coolant level in the coolant expansion tank has dropped
less than 30 mm, the cooling system has been filled correctly.

1.6 Flushing cooling system


The cooling system must be flushed, after the following compo‐
nents have been renewed:
♦ Cylinder head
♦ Heat exchanger for heater
♦ Radiator for engine coolant
♦ Radiator for charge air cooling circuit
♦ Intake manifold with charge air cooler
When flushing, the existing coolant is replaced by new coolant.
This will ensure optimum surface protection of the new compo‐
nents.

1. Cooling system/coolant 237


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ The coolant must be drained before the system is flushed.


Then the cooling system must be filled with distilled water.
♦ The cooling system is then flushed with approx. 12 litres
of distilled water. Then, the distilled water is replaced by
coolant (mixture ratio 50:50).
♦ After the coolant has been renewed, the cooling system is
bled using the ⇒ Vehicle diagnostic tester.
♦ Never reuse old coolant.
♦ For a quick reference guide, refer to ⇒ c1.6.1 ooling sys‐
tem, quick reference guide”, page 260 . The quick reference
guide contains the basic steps of the procedure. It might be
helpful to print out the guide and tick off the corresponding
work steps after having performed them.

Special tools and workshop


equipment required

♦ Coolant flushing and filling device -VAS 531 007-


♦ Test adapter -VAS 691 005/5-
♦ Spring-type clip pliers -VAS 6362-

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Suction-jet pump from cooling system charge unit -VAS


6096-
♦ Refractometer -T10007 A-
♦ Compressed air connection with 6 … 10 bar(g)
Schematic overview of coolant flushing and filling device -VAS
531 007-:

1. Cooling system/coolant 239


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Container with distilled wa‐


ter
❑ Fill with at least 20 l of
distilled water
❑ 12 litres of this are re‐
quired for flushing
❑ 8 litres are a safety re‐
serve and remain in the
canister
2 - Container with coolant
❑ Fill with at least 20 l of
coolant
❑ Anti-freeze to ap‐
prox. -36°C (mixture ra‐
tio 50:50)
❑ 12 litres of this are re‐
quired for flushing
❑ 8 litres are a safety re‐
serve and remain in the
canister
3 - Empty container
❑ For used coolant
4 - Empty container
❑ For used coolant
5 - Suction hose
❑ Comes from connection
2 on sight glass
6 - Sight glass
❑ When opaque, clean
sight class with a nylon
brush
7 - Pump
❑ Cut-out pressure approx. 1.5 bar
8 - Valve block
❑ With pressure gauge and shut-off taps
9 - Drain hose
❑ Connected to valve block for releasing pressure
10 - Flushing hose
❑ Connected to breather hose of coolant expansion tank for flushing
❑ Comes from connection 1 on sight glass
❑ Seal with plugs when not in use
11 - Plug
12 - Hose clamps
❑ Qty. 4
13 - Cleaning adapter
❑ Approx. 15 cm in length
❑ For cleaning coolant flushing and filling device after flushing
❑ Connected between valve block and flushing hose ⇒ Item 10 (page 240) (10)
14 - Extraction adapter
❑ Approx. 100 cm in length

240 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Connected to suction hose ⇒ Item 5 (page 240) (5) for extracting coolant

Preparing coolant flushing and filling device -VAS 531 007-:


– Fill container »1« with at least 20 l of distilled water.
– Fill container »2« with at least 20 l of coolant. Mixture ratio is
50:50 for frost protection down to approx. -36 °C.
– Empty containers »3« and »4«.
– Connect battery charger.
– Remove valve block from plug-in connector on equipment
trolley.
– Connect coolant flushing and filling device -VAS 531 007- to
battery.
Bleeding coolant flushing and filling device -VAS 531 007-:

– Connect suction hose -A- to container »1« with distilled wa‐


ter.
– Connect drain hose -arrow- to plug-in connector -B- on valve
block.

– Close shut-off taps -A- and -B-.

1. Cooling system/coolant 241


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

Do not fit the valve block onto the test adapter -VAS 691 005/5-.
The filler hose must be bled first.

– Switch on pump for -VAS 531 007-.


– Open cut-off tap -A-.
– Open shut-off tap -B- briefly to bleed filler hose.
– Close shut-off taps -A- and -B-.
Connecting coolant flushing and filling device -VAS 531 007-:

– Open cap -1- on coolant expansion tank.


– Screw test adapter -2- (-VAS 691 005/5-) onto coolant ex‐
pansion tank -1-.

– Pull drain hose -arrow- off plug-in connector -B- on valve


block.

242 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Fit valve block -1- onto test adapter -2-.

– Connect suction-jet pump -2- from -VAS 6096- to plug-in


connector -B- on valve block -1-.

Note

Aside from the suction-jet pump, the electric vacuum pump -VAS 6096/2- can also be used to generate a
vacuum. Connect electric vacuum pump and generate a vacuum, see ⇒ page 229 .

Filling cooling system with distilled water:

1. Cooling system/coolant 243


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– Place end of vent hose -8- of suction-jet pump into a con‐


tainer.
– Connect compressed air hose -6- to suction-jet pump -7-.
– Open shut-off tap -B- on valve block -5-.
• The suction-jet pump reduces pressure in the cooling sys‐
tem to below atmospheric pressure. The pointer of the pres‐
sure gauge must fall to at least -0.85 bar.
– Close shut-off tap -B-.
– Pull off compressed air hose -6-.
– Observe pressure gauge. The pointer of the pressure gauge
must remain stationary at -0.85 bar at least. The vacuum in
the cooling system is then sufficient for subsequent filling.

Note

♦ If the vacuum drops, the cooling system must be checked for leaks.
♦ The vacuum that builds up depends on the pressure in the compressed air system.

• The pump of the -VAS 531 007- must be switched on.

244 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– »Slowly« open shut-off tap -A-.


• The vacuum in the cooling system causes the distilled water
to be drawn into the cooling system, and thus causes the
cooling system to be filled. In addition, the pump of the -VAS
531 007- feeds distilled water into the coolant expansion
tank.
• After filling, the pressure in the coolant expansion tank must
be released. Proceed as follows to do this:
– Close shut-off tap -A- after filling.
– Remove suction-jet pump -2- from valve block -1- .

– Connect drain hose -arrow- to plug-in connector. Open shut-


off tap -B-, and leave it open so that the pressure in the
cooling system releases.

1. Cooling system/coolant 245


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Flushing cooling system with distilled water:

– Remove breather hose -2- from coolant expansion tank -1- .


– Connect breather hose -2- from coolant expansion tank to
flushing hose -1-.

– Seal connection on coolant expansion tank using plug -3-.


Secure plug with a hose clip.
– Close shut-off tap -B-.
– Remove engine cover panel.
Vehicles with variable valve timing:
– Remove air filter housing ⇒ page 443 .
Continued for all vehicles:
The cooling system consists of the following coolant circuits:
♦ Cylinder block and cylinder head
♦ Heat exchanger for heater
♦ Radiator for engine coolant
♦ Charge air cooler and water radiator for charge air cooling
circuit

246 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ During the procedure below, the 4 coolant circuits are flush‐


ed systematically by alternately clamping off the breather
hoses.
♦ This procedure must be performed twice with distilled water.
The circuits are then flushed twice with coolant.
♦ The indicated litre values are average values and may differ
depending on the vehicle equipment. The quantity can be
read on the scale of the container.
♦ The required quantity for flushing is determined by the
change in colour on connection 1 of the sight glass. It takes
two flushing cycles until the colour on connection 1 and 2 of
the sight glass is the same.
♦ If a change in colour can be seen in the sight glass, the next
coolant circuit is flushed.

1. Flushing cylinder block and cylinder head with distilled water:

1. Cooling system/coolant 247


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

A non-return valve -1- is installed in the breather hose of the charge air cooler. Therefore, the hose can be
clamped off only at the position shown.

– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Distilled water is now
pumped through the engine.
– Observe sight glass: if coolant starts to discolour, close shut-
off tap -A-.
• Required quantity of distilled water: approx. 2 to 3 l
2) Flushing heat exchanger for heater and turbocharger with
distilled water:

– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Distilled water is now
pumped through the engine.

248 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Observe sight glass: if coolant starts to discolour, close shut-


off tap -A-.
• Required quantity of distilled water: approx. 2 l
3. Flushing radiator with distilled water:

– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Distilled water is now
pumped through the engine.
– Observe sight glass: if coolant starts to discolour, close shut-
off tap -A-.
• Required quantity of distilled water: approx. 2 l
4 Flushing charge air cooler and water radiator for charge air
cooling circuit with distilled water:

1. Cooling system/coolant 249


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– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Distilled water is now
pumped through the engine.
– Observe sight glass: if coolant starts to discolour, close shut-
off tap -A-.
• Required quantity of distilled water: approx. 2 l

250 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Repeat flushing cycles 1 to 4 but use only approx. 1 l of distilled


water for each cycle ⇒ page 247 . Then flush cooling system
with coolant.
Flushing cooling system with coolant

– Connect suction hose -A- to container -2- for coolant.


1. Flushing cylinder block and cylinder head with coolant:

1. Cooling system/coolant 251


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– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Coolant is now pum‐
ped through the engine.
– Observe sight glass: if coolant can be seen to be discharged
through the sight glass, close shut-off tap -A-.
• Required quantity of coolant: approx. 2 to 3 l
2) Flushing heat exchanger for heater and turbocharger with
coolant:

– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Coolant is now pum‐
ped through the engine.
– Observe sight glass: if coolant can be seen to be discharged
through the sight glass, close shut-off tap -A-.
• Required quantity of coolant: approx. 2 l
3. Flushing radiator with coolant:

252 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Coolant is now pum‐
ped through the engine.
– Observe sight glass: if coolant can be seen to be discharged
through the sight glass, close shut-off tap -A-.
• Required quantity of coolant: approx. 2 l
4 Flushing charge air cooler and water radiator for charge air
cooling circuit with coolant:

1. Cooling system/coolant 253


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– Use hose clamps to clamp off breather hoses at the posi‐


tions shown.
– Open shut-off tap -A- on valve block. Coolant is now pum‐
ped through the engine.
– Observe sight glass: if coolant can be seen to be discharged
through the sight glass, close shut-off tap -A-.
• Required quantity of coolant: approx. 2 l
Repeat flushing cycles 1 to 4, but use only approx. 1 l of coolant
for each cycle ⇒ page 251 . Then, the flushing procedure has
been completed.
– Upon completion of flushing procedure switch off pump.
– Remove any hose clamps.

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Removing coolant flushing and filling device -VAS 531 007-:

– Open shut-off tap -B-, and leave it open so that the pressure
in the cooling system releases.
– Pull plug -3- off coolant expansion tank, and reconnect
breather hose -2-.

– Use plug to seal flushing hose -1-.


– Remove valve block -1- and test adapter -2-.

– Coolant level must be approx. at »weld seam« -arrow A-.

1. Cooling system/coolant 255


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– Extract or fill coolant as necessary.


Extracting coolant:

Note

Use the extraction adapter ⇒ Item 14 (page 240) to extract the coolant.

– Detach suction hose -5- from container -2-.

256 Rep. gr.19 - Cooling


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– Fit extraction adapter -12- onto plug-in connector of suction


hose -5-.
– Switch on pump -7-, and open shut-off taps -A- and -B- on
valve block -8-.
– Use extraction adapter -12- to extract any excess coolant.
– Close shut-off taps on valve block, and switch off pump.
Bleeding cooling system:
– On vehicles with auxiliary heater, switch on auxiliary heater
for about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in button should not light up.
– Connect vehicle diagnostic tester.
– Switch on ignition and select the following menu options on
vehicle diagnostic tester:
♦ 0001 - Engine electronics
♦ 0001 - Engine electronics functions
♦ 0001 - Filling coolant circuit

Note

The cooling system is mostly bled through flushing alone.


Consequently, a »shorter« bleeding routine is then necessary.
Answer the question “Was the cooling system filled with the
aid of electric vacuum pump VAS 6096/2?” with “yes” so that
the »shorter« bleeding routine can be initiated.

– Follow instructions shown on vehicle diagnostic tester.


– Check coolant level and frost protection.
– If the frost protection is not sufficient, extract coolant from
coolant expansion tank. Ensure correct anti-freeze protec‐
tion by filling more coolant concentrate.
– After each time coolant concentrate has been filled, run en‐
gine at increased engine speed for about 2 minutes, and
check anti-freeze protection again.
• Anti-freeze protection must be guaranteed down to -25°C as
a minimum and, in countries with arctic conditions, down
to approx. -36°C. Increasing the anti-freeze protection is
permissible only if climatic conditions require stronger anti-
freeze protection. It may, however, be increased only to a
maximum of -48°C. Otherwise, the cooling effect will be im‐
paired.
• When the engine is at operating temperature, the coolant
level must be at the »weld seam« -arrow A-.

1. Cooling system/coolant 257


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• When the engine is cold, the coolant level must be approx.


5 mm above the max. marking -arrow B-.

Note

This excessive amount of coolant level is necessary since the


coolant level may decrease automatically due to bleeding proc‐
ess.

Cleaning coolant flushing and filling device -VAS 531 007-:

258 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ If coolant remains in the sight glass for longer periods of time, the sight glass may become opaque.
Therefore, the sight glass must be flushed with distilled water after the flushing procedure has been
completed.
♦ If the sight glass is opaque, clean with a nylon brush.
♦ Use cleaning adapter ⇒ Item 13 (page 240) to flush.

– Connect suction hose -5- to container -1- for distilled water.


– Fit flushing hose -10- onto cleaning adapter -9-. Fit cleaning
adapter -9- to plug-in connector -B- on valve block -8-.
– Open shut-off valves -A- and -B- on valve block -8-.
– Switch on pump -7-, and pump distilled water through hoses
until coolant has been flushed out of sight glass -6-.
– Switch off pump, and close shut-off taps.
– Remove cleaning adapter, and seal flushing hose with plug.

1. Cooling system/coolant 259


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.6.1 Flushing cooling system, quick refer‐


ence guide

Note

The quick reference guide contains the basic steps of the pro‐
cedure. It might be helpful to print out the guide and tick off
the corresponding work steps after having performed them. For
a detailed description of the necessary work steps, refer to ⇒
page 237 .

Step Measure Volume of flush‐


ing medium
1 Draining coolant ---
2 Fill cooling system with distilled water ---
3 Fit breather hose from coolant expansion tank to cooling flushing and charging ---
unit
4 Clamp off breather hose for heat exchanger -1-, for radiator -3- and charge air 3 l of distilled wa‐
cooler -4-; flush cooling system ter
5 Clamp off breather hose for cylinder head -2-, for radiator -3- and charge air 2 l of distilled wa‐
cooler -4-; flush cooling system ter
6 Clamp off breather hose for heat exchanger -1-, for cylinder head -2- and charge 2 l of distilled wa‐
air cooler -4-; flush cooling system ter
7 Clamp off breather hose for heat exchanger -1-, for cylinder head -2- and radiator 2 l of distilled wa‐
-3-; flush cooling system ter
Repeat steps 4, 5, 6 and 7 but only pump through 1 litre of distilled water in each 1 litre of distilled
case water in each
case
8 Clamp off breather hose for heat exchanger -1-, for radiator -3- and charge air 3 l of coolant
cooler -4-; flush cooling system
9 Clamp off breather hose for cylinder head -2-, for radiator -3- and charge air 2 l of coolant
cooler -4-; flush cooling system
10 Clamp off breather hose for heat exchanger -1-, for cylinder head -2- and charge 2 l of coolant
air cooler -4-; flush cooling system
11 Clamp off breather hose for heat exchanger -1-, for cylinder head -2- and radiator 2 l of coolant
-3-; flush cooling system
Repeat steps 8, 9, 10 and 11 but only pump through 1 litre of coolant in each 1 litre of coolant
case in each case
12 Remove all clamping pliers ---
13 Detach coolant flushing and filling device, and close coolant expansion tank ---
14 Bleed cooling system with vehicle diagnostic tester ---
15 Check coolant level and frost protection ---

Clamp off points

260 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Breather hose of heat ex‐


changer for heater unit
2 - Breather hose for cylinder
head
3 - Breather hose of radiator
for engine coolant
4 - Charge air cooler hoses

1. Cooling system/coolant 261


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Coolant pump, regulation of cooling


system
⇒ o2.1 verview - coolant pump, thermostat”, page 262
⇒ o2.2 verview - electric coolant pump”, page 266
⇒ o2.3 verview - coolant temperature sender”, page 268
⇒ o2.4 verview - actuator for engine temperature regula‐
tionN493”, page 269
⇒ a2.5 nd installing electric coolant pump”, page 271
⇒ a2.6 nd installing coolant pump”, page 277
⇒ a2.7 nd installing thermostat”, page 278
⇒ t2.8 hermostat”, page 282
⇒ a2.9 nd installing coolant valve for cylinder headN489”, page
283
⇒ a2.10 nd installing coolant temperature senderG62”, page
283
⇒ a2.11 nd installing coolant temperature sender 2G802”, page
285
⇒ a2.12 nd installing actuator for engine temperature regula‐
tionN493”, page 287

2.1 Assembly overview - coolant pump,


thermostat
⇒ o2.1.1 verview - coolant pump/thermostat, version 1”, page
262
⇒ o2.1.2 verview - coolant pump/thermostat, version 2”, page
264

2.1.1 Assembly overview - coolant pump/thermostat, version 1

262 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - O-ring
❑ Renew after removal
❑ Moisten with coolant
2 - Union
3 - O-ring
❑ Renew after removal
❑ Moisten with coolant
4 - Front coolant pipe, bottom
❑ Removing and instal‐
ling ⇒ page 305
5 - Seal
❑ Renew after removal
6 - O-ring
❑ Renew after removal
❑ Moisten with coolant
7 - Coolant pump
❑ Removing and instal‐
ling ⇒ page 277
8 - O-ring
❑ Renew after removal
❑ Moisten with coolant
9 - Bolt
❑ 8 Nm
10 - Coolant valve for cylinder
head -N489-
❑ Removing and instal‐
ling ⇒ page 283
11 - Bolt
❑ Renew after removal
❑ 20 Nm +45°
12 - Retaining clip
❑ Ensure firm seating
13 - Retaining clip
❑ Ensure firm seating
14 - O-ring
❑ Renew after removal
❑ Moisten with coolant
15 - Seal
❑ Renew after removal
16 - Bolt
❑ 20 Nm
17 - Thermostat housing
18 - O-ring
❑ Renew after removal
❑ Moisten with coolant
19 - Thermostat

2. Coolant pump, regulation of cooling system 263


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Removing and installing ⇒ a2.7.1 nd installing thermostat, version 1”, page 278
20 - Bolt
❑ 20 Nm
21 - Union

2.1.2 Assembly overview - coolant pump/thermostat, version 2

264 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Coolant pump
❑ Removing and instal‐
ling ⇒ page 277
2 - O-ring
❑ Renew after removal
❑ Moisten with coolant
3 - O-ring
❑ Renew after removal
❑ Moisten with coolant
4 - Front coolant pipe, bottom
❑ Removing and instal‐
ling ⇒ page 305
5 - Retaining clip
❑ Ensure firm seating
6 - Seal
❑ Renew after removal
7 - Thermostat housing
8 - Bolt
❑ 20 Nm
9 - O-ring
❑ Renew after removal
❑ Moisten with coolant
10 - Thermostat
❑ Removing and instal‐
ling ⇒ page 279
11 - O-ring
❑ Renew after removal
❑ Moisten with coolant
12 - Union
13 - Retaining clip
❑ Ensure firm seating
14 - O-ring
❑ Renew after removal
❑ Moisten with coolant
15 - Bolt
❑ 8 Nm
16 - Bolt
❑ 8 Nm
17 - Retaining clip
❑ Ensure firm seating
18 - O-ring
❑ Renew after removal
❑ Moisten with coolant
19 - O-ring
❑ Renew after removal
❑ Moisten with coolant

2. Coolant pump, regulation of cooling system 265


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

20 - O-ring
❑ Renew after removal
❑ Moisten with coolant
21 - Bolt
❑ 8 Nm
22 - Coolant valve for cylinder head -N489-
❑ Removing and installing ⇒ page 283
23 - Bolt
❑ Renew after removal
❑ 20 Nm +45°

2.2 Assembly overview - electric coolant pump

266 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Retaining bracket
2 - Clip
3 - Connection
❑ To actuator for engine
temperature regulation
-N493-
❑ Coolant hose schemat‐
ic diagram ⇒ page 207
4 - Coolant hose
5 - Connection
❑ To front and front right
coolant pipes
❑ Coolant hose schemat‐
ic diagram ⇒ page 207
6 - Coolant hose
7 - Clip
8 - Bolt
❑ 40 Nm
9 - Bracket
❑ For charge air cooling
pump -V188-.
10 - Welded nut
11 - Charge air cooling pump
-V188-
❑ Removing and instal‐
ling ⇒ page 271
12 - Connection
❑ To rear coolant pipes
❑ Coolant hose schemat‐
ic diagram ⇒ page 207
13 - Clip
14 - Connection
❑ To rear coolant pipes
❑ Coolant hose schematic diagram ⇒ page 207
15 - Coolant hose
16 - Clip
17 - Auxiliary pump for heating -V488-
❑ Removing and installing ⇒ page 274
18 - Bracket
❑ for auxiliary pump for heating -V488-
19 - Retaining bracket
20 - Bolt
❑ 9 Nm
21 - Bolt
❑ 40 Nm

2. Coolant pump, regulation of cooling system 267


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.3 Assembly overview - coolant tempera‐


ture sender
⇒ o2.3.1 verview - coolant temperature senderG62”, page 268
⇒ o2.3.2 verview - coolant temperature sender 2G802”, page
268

2.3.1 Assembly overview - coolant temperature sender -G62-

1 - Connector
2 - Bolt
❑ 8 Nm
3 - Radiator outlet coolant -
G62-
❑ Removing and instal‐
ling ⇒ page 283
4 - O-ring
❑ Renew after removal
❑ Moisten with coolant
5 - Spacer ring
❑ Renew if damaged

2.3.2 Assembly overview - coolant temperature sender 2 -G802-

268 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bolt
❑ 8 Nm
2 - Coolant pipe
❑ At front below intake
manifold
❑ Removing and instal‐
ling ⇒ page 302
3 - Spacer ring
❑ Renew if damaged
4 - O-ring
❑ Renew after removal
❑ Moisten with coolant
5 - Coolant temperature send‐
er 2 -G802-
❑ Removing and instal‐
ling ⇒ page 285
6 - Connector
7 - Bolt
❑ 8 Nm

2.4 Assembly overview - actuator for en‐


gine temperature regulation -N493-
⇒ o2.4.1 verview - actuator for engine temperature regula‐
tionN493, Passat and Arteon”, page 269
⇒ o2.4.2 verview - actuator for engine temperature regula‐
tionN493, Tiguan”, page 270

2.4.1 Assembly overview - actuator for engine temperature regulation -N493-,


Passat and Arteon

2. Coolant pump, regulation of cooling system 269


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bracket
2 - Spacer
❑ Ensure proper seating
in bracket
3 - Sleeve
4 - Bolt
❑ 5 Nm
5 - Actuator for engine tem‐
perature regulation -N493-
❑ Removing and instal‐
ling ⇒ page 287
6 - Bolt
❑ 5 Nm
7 - Sleeve
8 - Spacer
❑ Ensure proper seating
in bracket
9 - Nut
❑ 20 Nm

2.4.2 Assembly overview - actuator for engine temperature regulation -N493-,


Tiguan

270 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bracket
❑ Secured to longitudinal
member with 3 nuts
❑ 20 Nm
2 - Bracket
3 - Spacer
❑ Ensure proper seating
in bracket
4 - Sleeve
5 - Bolt
❑ 5 Nm
6 - Nut
❑ 20 Nm
7 - Actuator for engine tem‐
perature regulation -N493-
❑ Removing and instal‐
ling ⇒ page 287
8 - Bolt
❑ 5 Nm
9 - Sleeve
10 - Spacer
❑ Ensure proper seating
in bracket
11 - Nut
❑ 20 Nm

2.5 Removing and installing electric cool‐


ant pump
⇒ a2.5.1 nd installing charge air cooling pumpV188”, page 271
⇒ a2.5.2 nd installing auxiliary pump for heatingV488”, page
274

2.5.1 Removing and installing charge air


cooling pump -V188-
Special tools and workshop equipment required

2. Coolant pump, regulation of cooling system 271


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

♦ Drip tray for workshop hoist -VAS 6208-

Removing
– Open cap -1- on coolant expansion tank.

272 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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
carefully to release pressure.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
Remove charge air cooling pump -V188- to free up space:

– Release and unplug electrical connector -7-.


– Unscrew bolt -6-, and remove arm -2-.
– Remove charge air cooling pump -V188- -1-, and tie it up on
the side.
Removing charge air cooling pump -V188-:

– Release and unplug electrical connector -7-.

Note

Place a cloth underneath to catch escaping coolant.

– Place drip tray for workshop hoist -VAS 6208- underneath.


– Clamp off coolant hoses -3- using hose clamps, up to 25 mm
-3094-.
– Release hose clips -arrows- and detach coolant hoses.

2. Coolant pump, regulation of cooling system 273


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolt -6-, and remove arm -2-.


– Remove charge air cooling pump -V188- -1-.
Removing charge air cooling pump -V188- together with bracket
from engine:

Note

This work step is required if the charge air cooling pump -V188-
must be removed together with the bracket in order to free
some space.

– Release and unplug electrical connector -7-.


– Remove bracket from engine. To do this, unscrew bolts -4-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o2.2 verview - electric coolant pump”, page 266
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.5.2 Removing and installing auxiliary pump


for heating -V488-
Special tools and workshop equipment required

274 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

♦ Drip tray for workshop hoist -VAS 6208-

– Open cap -1- on coolant expansion tank.

2. Coolant pump, regulation of cooling system 275


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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
carefully to release pressure.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
Removing auxiliary pump for heating -V488-:

– Release and unplug electrical connector -7-.

Note

Place a cloth underneath to catch escaping coolant.

– Place drip tray for workshop hoist -VAS 6208- underneath.


– Clamp off coolant hoses -3- using hose clamps up to 25 mm
-3094-.
– Release hose clips -arrows- and detach coolant hoses.
– Unscrew bolt -6-, and remove arm -2-.
– Remove auxiliary pump for heating -V488- -1-.
– Remove bracket from engine ⇒ page 266 .
Remove auxiliary pump for heating -V488- together with bracket
from engine:

276 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

This work step is required if the auxiliary pump for heating


-V488- must be removed in order to free some space.

– Release and unplug electrical connector -7-.


– Unscrew bolts -4-.
– Remove auxiliary pump for heating -V488- -5- together with
bracket -1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o2.2 verview - electric coolant pump”, page 266
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.6 Removing and installing coolant pump

Note

Checking function by pulling the regulator valve of the coolant


pump with your hand is not permitted. This can cause damage
to the coolant pump and lead to insufficient supply of coolant to
the engine.

Removing
– Drain coolant ⇒ page 213 .
– Remove toothed belt from camshaft ⇒ page 161 .
– Unscrew bolt -3-, and pull off coolant valve for cylinder head
-N489- -2-.

– Remove bolts -arrows- and detach coolant pump -1-.

2. Coolant pump, regulation of cooling system 277


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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

Note

Renew O-rings after removal.

– Clean and smooth down sealing surfaces for O-rings.


– Moisten O-rings with coolant.
– Install toothed belt (adjust valve timing) ⇒ page 152 .
– Add coolant ⇒ page 215 .
Specified torques
Stage Component Specified torque
1 Coolant 20 Nm
pump to en‐
gine
2 Coolant Turn 45° further
pump to en‐
gine
• ⇒ o2.1 verview - coolant pump, thermostat”, page 262
• ⇒ o2.1 verview - toothed belt cover”, page 138
• ⇒ o2.2 verview - toothed belt”, page 138

2.7 Removing and installing thermostat


⇒ a2.7.1 nd installing thermostat, version 1”, page 278
⇒ a2.7.2 nd installing thermostat, version 2”, page 279

2.7.1 Removing and installing thermostat,


version 1
Removing
– Note different versions ⇒ page 262 .
– Drain coolant ⇒ page 213 .
– Remove air filter housing ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Remove throttle valve module -J338- ⇒ page 456 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

278 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release catch -arrow B-.

– Turn connection -1- in direction of -arrow A- and disconnect.


– Remove thermostat.
Installing
Install in reverse order of removal, observing the following:

Note

Renew O-ring after each removal.

– Clean and flatten sealing surface for O-ring.


– Moisten O-ring with coolant.
– Fit thermostat -2- into thermostat housing.

• Retaining lugs must engage in guides -arrows-.


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 262
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ a4.6 nd installing radiator cowl”, page 333

2.7.2 Removing and installing thermostat,


version 2
Removing
– Note different versions ⇒ page 262 .

2. Coolant pump, regulation of cooling system 279


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove engine cover panel ⇒ page 61 .


– Drain coolant ⇒ page 213 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Remove throttle valve module -J338- ⇒ page 456 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Remove front coolant connection ⇒ page 301 .


– Remove front coolant pipes ⇒ page 299 .
– Loosen hose clip at top -arrow-.

– Pull coolant hose -2- off thermostat housing -1-.


– Unscrew nut -5- and remove bracket -6- from centre hex
stud -4-.

280 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -3- and -4-.


– Remove support, and push wiring harness to one side.
– Lift retaining clip -4- and disconnect coolant hose.

– Unscrew bolts -arrows-.

– Pull off connection -1-.


– Remove thermostat.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

2. Coolant pump, regulation of cooling system 281


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

Renew O-ring after each removal.

– Clean and flatten sealing surface for O-ring.


– Moisten O-ring with coolant.
– Insert thermostat -1- into thermostat housing -2-.

• The guides on the thermostat -1- must engage in the guide


-arrow- on the housing -2-.
– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 262
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o5.1 verview – intake manifold”, page 447
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

2.8 Checking thermostat


– Heat removed thermostat in water bath.
Starts to open Fully open Opening travel
87 ±2°C approx. 102°C 1) at least 9 mm
• 1) Not testable

282 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.9 Removing and installing coolant valve


for cylinder head -N489-
Removing

– Remove upper part of toothed belt guard ⇒ page 140 .


– Disconnect connector -2-, free off electrical wire.
– Unscrew bolt -3-, and detach coolant valve for cylinder head
-N489- -item 1-.
Installing
Install in reverse order of removal, observing the following:

Note

Renew O-rings after removal.

– Install upper toothed belt guard ⇒ page 140 .


Specified torques
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 262

2.10 Removing and installing coolant tem‐


perature sender -G62-
Removing
• Engine cold.
Fitting location ⇒ Item 2 (page 404) :
Assembly overview ⇒ page 268 :
– Open cap -1- on coolant expansion tank.

2. Coolant pump, regulation of cooling system 283


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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
carefully to release pressure.

– Remove engine cover panel ⇒ page 61 .


– Drain coolant ⇒ page 213 .
– Remove coolant pipe (top front) ⇒ page 298 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Remove front coolant connection ⇒ page 301 .


– Remove front right coolant pipe ⇒ page 303 .
– Remove front coolant pipe ⇒ page 299 .
– Remove coolant pipe at front below intake manifold ⇒ page
302 .
– Remove oil dipstick ⇒ page 184 .

Note

Place a cloth underneath to catch escaping coolant.

– Release connector -2- and pull off.

284 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolt -arrow-.


– Pull out coolant temperature sender -G62- -1-.

Note

♦ Insert new coolant temperature sender -G62- immediately


into cylinder head in order to avoid loss of coolant.
♦ If an O-ring or spacer ring remains lodged in cylinder head,
lift it out with a piece of wire.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew O-rings after removal.


♦ Renew spacer ring if damaged.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ o2.3 verview - coolant temperature sender”, page 268
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
♦ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.11 Removing and installing coolant tem‐


perature sender 2 -G802-
Removing
• Engine cold.
– Open cap -1- on coolant expansion tank.

2. Coolant pump, regulation of cooling system 285


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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
carefully to release pressure.

– Remove front coolant connection ⇒ page 301 .


– Remove right coolant pipe ⇒ page 303 .

Note

Place a cloth underneath to catch escaping coolant.

– Release connector -2- and pull off.

– Unscrew bolt -arrow-.


– Pull coolant temperature sender -G62- -1- out of coolant
pipe -3-.

Note

♦ Insert new coolant temperature sender -G62- immediately


into cylinder head in order to avoid loss of coolant.
♦ If an O-ring or spacer ring remains lodged in cylinder head,
lift it out with a piece of wire.

286 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew O-rings after removal.


♦ Renew spacer ring if damaged.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o2.3 verview - coolant temperature sender”, page 268
♦ ⇒ Electrical system; Rep. gr. 27; Alternator; Exploded view -
alternator
♦ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner com‐
pressor; Assembly overview - drive unit of air conditioner
compressor
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.12 Removing and installing actuator for


engine temperature regulation -N493-
⇒ a2.12.1 nd installing actuator for engine temperature regula‐
tionN493, Passat and Arteon”, page 287
⇒ a2.12.2 nd installing actuator for engine temperature regula‐
tionN493, Tiguan”, page 290

2.12.1 Removing and installing actuator for


engine temperature regulation -N493-,
Passat and Arteon
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

2. Coolant pump, regulation of cooling system 287


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Spring-type clip pliers -VAS 6362-

♦ Drip tray for workshop hoist -VAS 6208-

Remove actuator for engine temperature regulation -N493- ⇒


page 289 :
Remove actuator for engine temperature regulation -N493- to‐
gether with bracket from longitudinal member ⇒ page 289 :
– Open cap -1- on coolant expansion tank.

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
carefully to release pressure.

288 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Removing actuator for engine temperature regulation -N493-:

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and unplug electrical connector -4-.
– Place a cloth underneath to catch escaping coolant.
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Clamp off coolant hoses -2- using hose clamps, up to 25 mm
-3094-.
– Release hose clips -arrows- and detach coolant hoses.
– Unbolt actuator for engine temperature regulation -N493-
from bracket ⇒ Item 4 (page 270) .
Remove actuator for engine temperature regulation -N493- to‐
gether with bracket from longitudinal member:

Note

This work step is required if the actuator for engine tempera‐


ture regulation -N493- must be removed in order to free some
space.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and unplug electrical connector -4-.

– Unscrew nuts -3-.


– Remove actuator for engine temperature regulation -N493-
-1- together with bracket -2-.

2. Coolant pump, regulation of cooling system 289


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Tie up actuator for engine temperature regulation -N493-


together with bracket on the side.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o2.4 verview - actuator for engine temperature regula‐
tionN493”, page 269
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2.12.2 Removing and installing actuator for


engine temperature regulation -N493-,
Tiguan
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

290 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Drip tray for workshop hoist -VAS 6208-

Remove actuator for engine temperature regulation -N493- ⇒


page 291 :
Remove actuator for engine temperature regulation -N493- to‐
gether with bracket from longitudinal member ⇒ page 292 :
– Open cap -1- on coolant expansion tank.

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
carefully to release pressure.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
Removing actuator for engine temperature regulation -N493-:

2. Coolant pump, regulation of cooling system 291


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and unplug electrical connector -4-.


– Place a cloth underneath to catch escaping coolant.
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Clamp off coolant hoses -2- using hose clamps, up to 25 mm
-3094-.
– Release hose clips -arrows- and detach coolant hoses.
– Unbolt actuator for engine temperature regulation -N493-
from bracket ⇒ Item 5 (page 271) and ⇒ Item 8 (page 271) .
Remove actuator for engine temperature regulation -N493- to‐
gether with bracket from longitudinal member:

Note

This work step is required if the actuator for engine tempera‐


ture regulation -N493- must be removed in order to free some
space.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and unplug electrical connector -4-.

– Unscrew nuts -5-.


– Remove actuator for engine temperature regulation -N493-
-3- together with bracket.
– Tie up actuator for engine temperature regulation -N493-
together with bracket on the side.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o2.4 verview - actuator for engine temperature regula‐
tionN493”, page 269

292 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐


tion; Assembly overview - noise insulation

2. Coolant pump, regulation of cooling system 293


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 Coolant pipes
⇒ o3.1 verview - coolant pipes”, page 294
⇒ a3.2 nd installing coolant pipes”, page 298

3.1 Assembly overview - coolant pipes

Note

The arrow markings on coolant pipes and on ends of coolant hoses must align.

294 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front coolant pipe


❑ Removing and instal‐
ling ⇒ page 299
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ 8 Nm
4 - Coolant pipe at front below
intake manifold
❑ Removing and instal‐
ling ⇒ page 302
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
7 - Rear right coolant pipe
❑ Removing and instal‐
ling ⇒ page 313
8 - O-ring
❑ Renew after removal
❑ Moisten with coolant
9 - Bolt
❑ 10 Nm
10 - Centre hex stud
❑ 23 Nm
11 - Rear coolant pipe
❑ Removing and instal‐
ling ⇒ page 310
12 - Bolt
❑ 8 Nm
13 - Left upper coolant pipe
14 - Bolt
❑ 8 Nm
15 - Upper left coolant pipe on cylinder head cover
❑ Removing and installing ⇒ page 315
16 - Bolt
❑ 8 Nm
17 - Bolt
❑ 8 Nm
18 - Left coolant pipes
❑ Removing and installing ⇒ page 308
19 - Bolt
❑ 8 Nm

Install front right coolant pipe

3. Coolant pipes 295


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Install front right coolant pipe


2 - Coolant hose
3 - Clip
Pfeil - Bolt 8 Nm
Coupling point for coolant pipes on left in engine compartment:

296 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Retaining clip
2 - Union
3 - Hose clamp
4 - Coolant hose
5 - Hose clamp
6 - Coolant pipe
❑ On vehicles with auxili‐
ary heater, coolant pipe
leads to connection ⇒
Item 30 (page 298)
7 - Retaining clip
8 - Retaining clip
9 - Coolant pipe
❑ To heat exchanger for
heater
10 - Bleeder valve
11 - Coolant hose
12 - Coolant hose
13 - Coolant hose
❑ To left coolant pipe ⇒
Item 18 (page 295)
14 - Coolant hose
❑ To exhaust gas recircu‐
lation cooler
15 - Coolant hose
❑ To exhaust gas recircu‐
lation cooler
16 - Coolant hose
❑ To coolant pipe on low
pressure turbocharger ⇒ Item 12 (page 345)
17 - Hose clamp
18 - Coolant hose
19 - Hose clamp
20 - Coolant hose
❑ For vehicles with auxiliary heating
21 - Coolant hose
❑ For vehicles with auxiliary heating
22 - Retaining clip
23 - Retaining clip
24 - Coolant pipes
❑ For vehicles with auxiliary heating
25 - Hose clamp
26 - Retaining clip
27 - Coolant hose
❑ For vehicles with auxiliary heating
28 - Heat protection

3. Coolant pipes 297


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

29 - Hose clamp
30 - Union

3.2 Removing and installing coolant pipes


⇒ a3.2.1 nd installing upper front coolant pipe”, page 298
⇒ a3.2.2 nd installing front coolant pipes”, page 299
⇒ a3.2.3 nd installing front coolant connection”, page 301
⇒ a3.2.4 nd installing coolant pipe at front below intake mani‐
fold”, page 302
⇒ a3.2.5 nd installing front right coolant pipe”, page 303
⇒ a3.2.6 nd installing lower front coolant pipe”, page 305
⇒ a3.2.7 nd installing left coolant pipes”, page 308
⇒ a3.2.8 nd installing rear coolant pipe”, page 310
⇒ a3.2.9 nd installing rear right coolant pipe”, page 313
⇒ l3.2.10 eft coolant pipe on cylinder head cover”, page 315
⇒ a3.2.11 nd installing upper left coolant pipes”, page 317
⇒ a3.2.12 nd installing coolant pipes on turbocharger”, page
320

3.2.1 Removing and installing upper front


coolant pipe
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

♦ Hose clamps to 25 mm -3094-

Removing
– Remove engine cover panel ⇒ page 61 .

298 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Clamp off coolant hoses to front top coolant pipe using hose
clamps, up to 25 mm -3094-.
– Open clips, and pull coolant hoses -arrows- off water pipe
-1-.

– Unscrew bolts -2-.


– Remove top coolant pipe at front.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Add coolant ⇒ page 215 .


– Fit engine cover panel ⇒ page 61 .

3.2.2 Removing and installing front coolant


pipes
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove coolant pipe (top front) ⇒ page 298 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .

3. Coolant pipes 299


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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


illustration.

– Remove front coolant connection ⇒ page 301 .


– Unscrew bolts -2-.

– Open clips -arrows-, and pull coolant hoses off water pipes
-1-.
– Unscrew bolt -2-.

– Open clips, and pull coolant hoses -arrows- off water pipe
-1-.
– Unclip wiring harness.
– Detach coolant pipes.

300 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.2.3 Removing and installing front coolant


connection
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Open clamps -arrows-.

3. Coolant pipes 301


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull off coolant hoses.


– Release retaining clip in -direction of arrow-, and pull off
connecting piece -1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Add coolant ⇒ page 215 .


– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

3.2.4 Removing and installing coolant pipe at


front below intake manifold
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

302 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Removing
– Remove intake manifold ⇒ page 450 .
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Add coolant ⇒ page 215 .


Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
♦ ⇒ o5.1 verview – intake manifold”, page 447

3.2.5 Removing and installing front right


coolant pipe
Special tools and workshop equipment required
♦ Hose clamp pliers -VAS 6340-

♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .

3. Coolant pipes 303


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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


illustration.

– Remove poly V-belt ⇒ page 67 .


– Remove air conditioner compressor from bracket with re‐
frigerant lines connected ⇒ Heating, air conditioning; Rep.
gr. 87; Air conditioner compressor; Removing air conditioner
compressor from and installing to bracket, and tie it up to
right side.
– Release hose clips -3- and pull off coolant hoses.

– Unscrew bolt -arrow-.


– Remove front right coolant pipe -1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Add coolant ⇒ page 215 .


– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

304 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner com‐


pressor; Assembly overview - drive unit of air conditioner
compressor

3.2.6 Removing and installing lower front


coolant pipe
Removing
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct and air filter ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Remove throttle valve module -J338- ⇒ page 456 .


– Remove exhaust gas recirculation valve 1 -GX5- ⇒ page
607 .
– Remove coolant pipe (top front) ⇒ page 298 .
– Remove front coolant connection ⇒ page 301 .
– Remove front right coolant pipe ⇒ page 303 .
– Remove front coolant pipe ⇒ page 299 .
– Remove coolant pipe at front below intake manifold ⇒ page
302 .
– Remove oil filter housing ⇒ page 201 .
– Release hose clips -arrows-.

3. Coolant pipes 305


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull coolant hose -2- off thermostat housing -1-.


– Pull coolant hose -3- off oil filter housing -4-.
– Unscrew bolts -3-.

– Unscrew bolt -arrow-, and remove bracket -1-.

– Lift retaining clip -4- and disconnect coolant hose.

306 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows-.


– Pull off locking clip -2-.
– Pull thermostat housing -3- at bottom front off coolant pipe
-1-, and remove it.
– Release hose clip -1- and detach coolant hose.

– Unscrew bolt -4-.


– Pull off coolant pipe at bottom front -3-, and remove it.
– Do not damage vacuum line -2- while doing so.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew seals and O-rings after removal.


♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Clean and smooth down sealing surfaces for seals and O-


rings.
– Lubricate seals and O-rings with coolant.
– Install oil filter housing ⇒ page 201 .
– Connect coolant hose with plug-in connector ⇒ page 324 .
– Add coolant ⇒ page 215 .
Specified torques
Bolts Specified torque
Bracket to en‐ 20 Nm
gine
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 262
♦ ⇒ o5.1 verview – intake manifold”, page 447
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
♦ ⇒ o5.1.2 verview – exhaust gas recirculation, exhaust gas
recirculation valve 1GX5”, page 600

3. Coolant pipes 307


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner com‐


pressor; Assembly overview - drive unit of air conditioner
compressor

3.2.7 Removing and installing left coolant


pipes
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

♦ Hose clamp pliers -VAS 6340-

♦ Release tool -VAS 531 001-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct ⇒ page 443 .
– Remove air filter housing and air filter bracket ⇒ page 443 .
– Remove air pipe ⇒ page 382 .
– Unscrew bolt -3-.

308 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bracket -2- and lay aside.


– Unscrew bolts -arrows- to remove bracket -1-.
– Release retaining clip -arrow-.

– Pull coolant hose -2- off exhaust gas recirculation cooler -1-.
– Unscrew bolts -arrows A- to remove connection -1-.

– Unscrew bolts -3- to -5-.


– Release hose clips -arrows B- and detach coolant hoses.
– Guide left coolant pipes -2- forwards and remove.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

3. Coolant pipes 309


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Close clip -1- in direction of -arrow- using release tool -VAS


531 001-.

– Add coolant ⇒ page 215 .


Specified torques
♦ ⇒ o1.1 verview - cylinder head”, page 113
♦ ⇒ o5.1 verview – intake manifold”, page 447
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o2.1 verview - charge air system”, page 377

3.2.8 Removing and installing rear coolant


pipe
Special tools and workshop equipment required
♦ Drip tray for workshop hoist -VAS 6208-

♦ Hose clamp pliers -VAS 6340-

310 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Spring-type clip pliers -VAS 6362-

♦ Release tool -VAS 531 001-

Removing
– Open cap -1- on coolant expansion tank.

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
carefully to release pressure.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Unbolt propshaft from bevel box ⇒ Propshaft and rear final
drive; Rep. gr. 39; Propshaft.

3. Coolant pipes 311


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Place drip tray for workshop hoist -VAS 6208- underneath.


– Release hose clip -arrow B-, and remove coolant hose -2-
on coolant pipe -1-.

– Drain coolant.
– Unscrew nuts -arrows A-.
– Open clips -arrows B-, and pull coolant hoses -2- off coolant
pipe -1-.

– Unscrew bolt -arrow A-.


Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Close clip -1- in direction of -arrow- using release tool -VAS


531 001-.

312 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Add coolant ⇒ page 215 .


Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ a1.2 nd installing front exhaust pipe”, page 501
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner

3.2.9 Removing and installing rear right cool‐


ant pipe
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

♦ Release tool -VAS 531 001-

Removing
– Remove emission control module ⇒ page 523 .

3. Coolant pipes 313


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Open clip -arrow-, and remove coolant hose -3-.

– Unscrew bolts -2- and -4-, and remove rear right coolant
pipe -1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew O-ring after each removal.


♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Close clip -1- in direction of -arrow- using release tool -VAS


531 001-.

– Fit engine cover panel ⇒ page 61 .


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598

314 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ o2.1 verview – emission control”, page 516


♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

3.2.10 Upper left coolant pipe on cylinder


head cover
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Open filler cap -5- on coolant expansion tank.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

3. Coolant pipes 315


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Clamp off left and right coolant hoses using hose clamps up
to 25 mm -3094-.

– Open clip -A- and pull coolant hose off water pipe -1-.
– Unscrew bolts -arrows- for coolant pipe -1-.

– Pull heat protection hose towards rear.

316 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Clamp off coolant hose -2- with hose clamps up to 25 mm


-3094-.
– Open clip -3-, and pull coolant hose off turbocharger.
– Guide out coolant pipe and remove.
Installing:
– Fit engine cover panel ⇒ page 61 .
– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294

3.2.11 Removing and installing upper left


coolant pipes
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

Removing
– Remove engine cover panel ⇒ page 61 .
– Open filler cap -5- on coolant expansion tank.

3. Coolant pipes 317


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Loosen clamps -arrow-.

– Pull off water hoses -2- on intake manifold -1-.


– Release connector -1- and pull off.

318 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip vacuum lines.


– Pull connection piece of exhaust gas temperature sender 1
-G235- -2- off coolant pipes.
– Open clips -3-, and pull off water hoses -4-.

– Release and pull off connector -3- from charge pressure


sender -G31- -1-.

– Unscrew bolt -arrow- for charge pressure sender -G31- -1-.


– Lay charge pressure sender -G31- aside.
– Unscrew bolt -arrow- on coolant pipes -1-.

3. Coolant pipes 319


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip wires.
– Guide out and remove coolant pipes.
Installing:
– Fit engine cover panel ⇒ page 61 .
– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294

3.2.12 Removing and installing coolant pipes


on turbocharger
Special tools and workshop equipment required
♦ Engine support -T10533-

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Release and pull off connector -1- for oil level and oil tem‐
perature sender -G266-.

320 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -2- on auxiliary pump for


heating -V488-.
– To do this, open locking device -3- by pressing in direction of
-arrow- and release connector.
– Remove pendulum support ⇒ page 39 .
– Remove propshaft from bevel box ⇒ Propshaft and rear final
drive; Rep. gr. 39; Propshaft.
– Position engine support -T10533- -A- as shown.

– Engine support -T10533/2- -B- is positioned on flat bolt con‐


necting point of engine support -T10533/1-.
– Screw in original bolt of pendulum support -1- in front threa‐
ded hole of pendulum support.
– Screw bolt M8 × 60 mm -2- with washer into left threaded
hole of noise insulation.
– Between high bolt connecting point and subframe, engineer
a distance of 20 mm with washers -a-.
– Tighten bolts by hand.
– Using engine support -T10533-, push engine as far forwards
as possible.
– Ensure that there is sufficient clearance to all components.
– Removing and installing exhaust gas temperature sender 4
-G648- ⇒ page 595 .

3. Coolant pipes 321


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove exhaust gas recirculation valve 2 - GX6- ⇒ page


609 .
– Remove turbocharger 1 control unit - J724- ⇒ page 372 .
– Open clips -2- and pull off coolant hoses -3-.

– Unscrew bolts -arrows-, and remove water pipes -1-.


Installing:
– Renew seals -4-.

– Ensure that coolant pipe -2- sits in front of coolant pipe -1-
as shown.

Note

♦ Located on the coolant pipe -1- is a spacer -arrow- for this


purpose.
♦ An even installation position is achieved in this way.

– Screw in bolt -3- by hand and tighten.


Specified torque:
♦ ⇒ o1.1.3 verview - coolant lines on turbocharger”, page 344

322 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

4 Radiator, radiator fan


⇒ o4.1 verview - radiator/radiator fan”, page 323
⇒ o4.2 verview - auxiliary radiator”, page 325
⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
⇒ a4.4 nd installing radiator”, page 327
⇒ a4.5 nd installing water radiator for charge air cooling circuit”,
page 330
⇒ a4.6 nd installing radiator cowl”, page 333
⇒ a4.7 nd installing radiator fan”, page 336
⇒ a4.8 nd installing auxiliary radiator”, page 337

4.1 Assembly overview - radiator/radiator fan

4. Radiator, radiator fan 323


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Radiator for engine cool‐


ant
❑ Removing and instal‐
ling ⇒ page 327
2 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 324
3 - O-ring
❑ Renew if damaged
❑ Moisten with coolant
4 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 324
5 - O-ring
❑ Renew if damaged
❑ Moisten with coolant
6 - Air duct
7 - Air duct
8 - Rubber mounting
❑ For radiator
9 - Radiator for charge air
cooling circuit
❑ Removing and instal‐
ling ⇒ page 327
10 - Condenser
❑ Removing and instal‐
ling ⇒ Heating, air con‐
ditioning; Rep. gr. 87;
Refrigerant circuit; Removing and installing condenser
11 - Rubber mounting
❑ For radiator
12 - O-ring
❑ Renew if damaged
❑ Moisten with coolant
13 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ page 324
14 - O-ring
❑ Renew if damaged
❑ Moisten with coolant
15 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ page 324

Connecting coolant hose with plug-in connector

324 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Check seal -2- for damage, and renew it if necessary.


– Moisten O-ring with coolant, and insert it into coolant hose.
– Push coolant hose into connection -1- until it audibly engag‐
es.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.

4.2 Assembly overview - auxiliary radiator


The auxiliary radiator is not necessarily installed.

4. Radiator, radiator fan 325


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Auxiliary radiator
❑ Removing and instal‐
ling ⇒ page 337
2 - Clip
3 - Coolant hoses
4 - Nuts
❑ 8 Nm
5 - Bracket
6 - Bracket
❑ For auxiliary radiator
7 - Washer
8 - Bolt
❑ Qty. 2
❑ 3.5 Nm
9 - Decoupling element
❑ Ensure proper seating.

4.3 Assembly overview – radiator cowl and radiator fan

326 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bolt
❑ 5 Nm
2 - Radiator cowl
❑ Removing and instal‐
ling ⇒ page 333
3 - Bolt
❑ 5 Nm
4 - Radiator fan -V7-
❑ Removing and instal‐
ling ⇒ page 336
5 - Radiator fan 2 -V177-
❑ Removing and instal‐
ling ⇒ page 336

4.4 Removing and installing radiator


Special tools and workshop equipment required
♦ Drip tray for workshop hoist -VAS 6208-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.

4. Radiator, radiator fan 327


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Drain coolant ⇒ page 213 .


– Remove air filter housing ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Open retainers for refrigerant lines -arrows-.

– Unclip rear retainer for refrigerant lines on body.


– Push refrigerant lines to one side.
– Lift retaining clip -arrow- and disconnect coolant hose (top
left) from radiator.

Arteon:

– Lift retaining clip -arrow- and disconnect coolant hose (top


right) from water radiator for charge air cooling circuit.
– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.

328 Rep. gr.19 - Cooling


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Continued for all vehicles:

– Release locking tabs -arrow- for radiator on left and right.


When doing this, pull top of radiator backwards.
– To release, push a suitable screwdriver -A- from behind be‐
tween radiator for engine coolant -2- and radiator for charge
air cooling circuit -1-.

– Position screwdriver -A- as shown but do not lever when


doing so.
– Lift coolant radiator upwards off charge air cooling circuit
radiator.
– Remove radiator downwards.
Installing
Install in reverse order of removal. While doing so, observe the
following:

4. Radiator, radiator fan 329


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

If there are minor dents in the fins, refer to ⇒ page 8 .

– Renew O-rings if damaged.


– Position radiator at an angle in lower mounting of water ra‐
diator for charge air cooling circuit. Engage radiator/cooler
with one another. Ensure proper engagement by pulling.
– Connect coolant hose with plug-in connector ⇒ page 324 .

Caution

If a new radiator has been installed, the cooling system must


be flushed and the coolant must be renewed to ensure opti‐
mum surface protection ⇒ page 237 .

If the existing radiator has been installed:


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

4.5 Removing and installing water radiator


for charge air cooling circuit
Removing
– Drain coolant ⇒ page 213 .
– Unscrew air duct on lock carrier ⇒ page 443 .
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– If present, remove centre guide profile on lock carrier ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50; Lock carrier; Assem‐
bly overview - lock carrier.
– Remove upper cover -1-, release locking device -arrows- on
lock carrier for this.

– Remove radiator cowl ⇒ page 333 .


– Lift retaining clip -arrow- and disconnect coolant hose (top
right) from water radiator for charge air cooling circuit.

330 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows- and push to one side.

– To do this, release catches -3- in -direction of arrow-, and


pull off air ducts.
– Pull left and right air duct -2- upwards off condenser.

– Release catches on both sides -arrow A- and detach con‐


denser -3- from water cooler for charge air cooling circuit -1-.
– Tie up condenser to lock carrier.
– Removing radiator ⇒ page 327 .
– Using a side cutter, release or pinch open fasteners -arrows-
for radiator mounting on left and right. Push radiator at top
slightly towards engine.

4. Radiator, radiator fan 331


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

The radiator mounting will be reused when reinstalling the radi‐


ator. It will then be bolted to lock carrier. For bolts, refer to
⇒ Electronic parts catalogue (ETKA).

– Pull charge air cooling circuit radiator upwards out of mount‐


ings.
– Remove radiator for charge air cooling circuit downwards.
Installing
Install in reverse order of removal. While doing so, observe the
following:

Note

♦ If there are minor dents in the fins, refer to ⇒ page 8 .


♦ Renew O-rings after removal.

– Swing water radiator for charge air cooling circuit into lock
carrier. Ensure proper seating of radiator mountings in lock
carrier.
– Use bolts -arrows- to secure radiator mountings, whose fas‐
teners have been pinched off, to lock carrier. For bolts, refer
to ⇒ Electronic parts catalogue (ETKA).

Bolts Specified torque


Bolt -arrows- 5 Nm
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Removing and installing bumper
cover.

332 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Installing radiator ⇒ page 327 .


– Install radiator cowl ⇒ page 333 .
– Connect coolant hose with plug-in connector ⇒ page 324 .

Caution

If a new radiator has been installed, the cooling system must


be flushed and the coolant must be renewed to ensure opti‐
mum surface protection ⇒ page 237 .

If the existing radiator has been installed:


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
♦ ⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;
Removing and installing bumper cover
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview - lock carrier

4.6 Removing and installing radiator cowl


⇒ a4.6.1 nd installing radiator cowl, Passat”, page 333
⇒ a4.6.2 nd installing radiator cowl, Tiguan and Arteon”, page
335

4.6.1 Removing and installing radiator cowl,


Passat
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.

WARNING

Danger of injury; the radiator fans can run at any time.


♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl.

– Remove air filter housing ⇒ page 443 .


– Release and pull off connector -1- for radiator fan.

4. Radiator, radiator fan 333


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– To do this, push locking tab in -direction of arrow A-, and


press release mechanism.
– Simultaneously press locking tabs on left and right of radia‐
tor fan cowling -arrow B-.
– Remove radiator cowl downwards from radiator.

Note

To avoid damage to the radiator after the cowling is removed,


use protective mat -VAS 531003-.

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


illustration.

Installing
Install in reverse order of removal, observing the following:
– Engage radiator cowl in radiator. Ensure proper engagement
by pulling.
Specified torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

334 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

4.6.2 Removing and installing radiator cowl,


Tiguan and Arteon
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove air filter housing ⇒ page 443 .

WARNING

Danger of injury; the radiator fans can run at any time.


♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl.

– If necessary, release hose clip on upper left radiator connec‐


tion, and turn it.

– Pull connector -1- off radiator cowl.

– To do this, push securing clip in direction of -arrow A-, and


release connector.
– Using a suitable tool, release radiator cowl -3- from mount‐
ings at top -2-.

4. Radiator, radiator fan 335


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Simultaneously press locking lugs on left and right -arrow B-


of radiator -2-.
– Pull radiator cowl on both sides upwards out of mountings.
– Pull radiator cowl out of mountings at top -2- and bottom
-arrow C-.
– Remove radiator cowl downwards.

Note

To avoid damage to the radiator after the cowling is removed,


use protective mat -VAS 531003-.

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


illustration.

Installing
Install in reverse order of removal, observing the following:
Specified torques
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ Assembly overview - noise insulation ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Noise insulation; Assembly over‐
view - noise insulation

4.7 Removing and installing radiator fan


⇒ a4.7.1 nd installing radiator fan V7”, page 336
⇒ a4.7.2 nd installing radiator fan V177”, page 337

4.7.1 Removing and installing radiator fan -


V7-
Removing
– Remove radiator cowl ⇒ page 333 .
– Release and pull off connector -arrow-.

336 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Detach wiring harness from radiator cowl.


– Unscrew bolts -1-, and remove radiator fan -V7-.
Installing
Install in reverse order of removal, observing the following:
– Attach wiring harness to radiator cowl.
Specified torques
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

4.7.2 Removing and installing radiator fan -


V177-
Removing
– Remove radiator cowl ⇒ page 333 .
– Release and pull off connector -arrow-.

– Detach wiring harness from radiator cowl.


– Unscrew bolts -2-, and remove radiator fan -V177-.
Installing
Install in reverse order of removal, observing the following:
– Attach wiring harness to radiator cowl.
Specified torques
♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326

4.8 Removing and installing auxiliary radia‐


tor
The auxiliary radiator is not necessarily installed.
Special tools and workshop equipment required

4. Radiator, radiator fan 337


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Hose clamps to 25 mm -3094-

♦ Drip tray for workshop hoist -VAS 6208-

♦ Torque wrench -VAS 6854-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Remove lower section of front left wheel housing liner
⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview - front wheel housing liner.
– Remove front bumper covers ⇒ General body repairs, exteri‐
or; Rep. gr. 63; Front bumper; Assembly overview - bumper
cover.
– Clamp off coolant hoses to radiator before plug-in connector
-arrows- using hose clamps up to 25 mm -3094-.

338 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Place drip tray for workshop hoist -VAS 6208- beneath auxil‐
iary radiator.
– Remove coolant hoses -2-. To do this, release retaining clips
-arrows-.
– Drain coolant from auxiliary radiator.
– Unscrew nut -3- from auxiliary radiator -1-.
– Unclip wiring harness -3- on auxiliary radiator -arrows-.

– Pull air duct off mountings -4- on auxiliary radiator.


– To do this, pull air duct towards left and then towards front.
– Unscrew nuts -2-, and remove auxiliary radiator -1- together
with bracket.
– Remove auxiliary radiator from bracket ⇒ page 325 .
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ If there are minor dents in the fins, refer to ⇒ page 8 .


♦ Renew O-rings after removal.

– Connect coolant hose with plug-in connector ⇒ page 324 .


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ page 325
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323

4. Radiator, radiator fan 339


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ General body repairs, exterior; Rep. gr. 63; Front bumper;


Assembly overview - bumper cover
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner

340 Rep. gr.19 - Cooling


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

21 – Turbocharging/supercharging
1 Turbocharger
⇒ o1.1 verview - turbocharger”, page 341
⇒ a1.2 nd installing turbocharger”, page 354
⇒ a1.3 nd installing vacuum unit for turbocharger”, page 366
⇒ a1.4 nd installing turbocharger 1 control unitJ724”, page 372

1.1 Assembly overview - turbocharger


⇒ o1.1.1 verview - turbocharger”, page 341
⇒ o1.1.2 verview - heat shields on turbocharger”, page 343
⇒ o1.1.3 verview - coolant lines on turbocharger”, page 344
⇒ o1.1.4 verview - high-pressure turbocharger”, page 345
⇒ o1.1.5 verview - low-pressure turbocharger”, page 347
⇒ o1.1.6 verview - turbocharger/exhaust manifold”, page 349
⇒ o1.1.7 verview - senders and sensors on turbocharger”, page
351
⇒ o1.1.8 verview - oil lines on turbochargers”, page 352

1.1.1 Assembly overview - turbocharger

1. Turbocharger 341
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Low-pressure turbocharg‐
er
❑ Assembly overview - ⇒
page 347
❑ Removing and instal‐
ling ⇒ page 354
2 - Bolt
❑ Qty. 2
❑ 20 Nm
3 - Bracket
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Bolt
❑ Qty. 2
❑ For securing emission
control module
❑ 20 Nm
7 - Bolt
❑ Qty. 3
❑ 20 Nm
8 - Seal
❑ Renew after removal
9 - Exhaust manifold
❑ Assembly overview - ⇒
page 613
❑ Tightening sequence
and specified torque: ⇒
page 613
❑ Removing and instal‐
ling ⇒ page 614
10 - Seal
❑ Renew after removal
11 - Bolt
❑ Renew after removal
❑ Tightening sequence ⇒ page 347
❑ 20 Nm +135°
12 - Nut
❑ Qty. 4
❑ Renew after removal
❑ Tightening sequence ⇒ page 347
❑ 20 Nm
13 - High-pressure turbocharger
❑ Assembly overview - ⇒ page 345
❑ Removing and installing ⇒ page 354
14 - Bolt
❑ Qty. 2
❑ 8 Nm

342 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

15 - Air pipes
16 - Flexible joints
17 - Air pipes
18 - Oil seals
❑ Qty. 2
❑ Renew after removal
19 - Heat shield
20 - Bolt
❑ Qty. 2
❑ 8 Nm
21 - Bolt
❑ Qty. 2
❑ 20 Nm
22 - Bolt
❑ Qty. 2
❑ 20 Nm
23 - Bracket
24 - Bolt
❑ Qty. 2
❑ 20 Nm
25 - Bracket
26 - Bolt
❑ 8 Nm

1.1.2 Assembly overview - heat shields on turbocharger

1. Turbocharger 343
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Turbocharger
❑ Assembly overview ⇒
page 341
2 - Heat shield
3 - Bracket
4 - Bolt
❑ 8 Nm
5 - Heat shield
6 - Bracket
7 - Heat shield

1.1.3 Assembly overview - coolant lines on turbocharger

344 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Coolant pipe
2 - Coolant pipe
3 - Bolt
❑ 10 Nm
4 - Seal
❑ Renew after removal
5 - Coolant connection
6 - Turbocharger
❑ Assembly overview - ⇒
page 341
7 - Heat shield sleeve
8 - Seal
❑ Renew after removal
9 - Coolant pipe
❑ Removing and instal‐
ling ⇒ page 320
10 - Bolt
❑ 10 Nm
11 - Bolt
❑ Renew after removal
❑ 8 Nm
12 - Coolant pipe
❑ Removing and instal‐
ling ⇒ page 320
13 - Bolt
❑ Renew after removal
❑ 8 Nm
14 - Bolt
❑ Renew after removal
❑ 8 Nm

1.1.4 Assembly overview - high-pressure turbocharger

1. Turbocharger 345
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Exhaust manifold
❑ Assembly overview - ⇒
page 613
❑ Tightening sequence
and specified torque: ⇒
page 613
❑ Removing and instal‐
ling ⇒ page 614
2 - Seal
❑ Renew after removal
3 - High-pressure turbocharg‐
er
❑ Removing and instal‐
ling ⇒ page 354
❑ Tightening sequence ⇒
page 347
4 - Nut
❑ Qty. 4
❑ Renew after removal
❑ Tightening sequence ⇒
page 347
❑ 20 Nm
5 - Bolt
❑ Renew after removal
❑ Tightening sequence ⇒
page 347
❑ 20 Nm +135°
6 - Adapter
7 - Washer
8 - Retaining ring
9 - Turbocharger 1 control
unit -J724-
❑ Removing and installing ⇒ page 372
❑ With position sender for charge pressure positioner -G581-
10 - Bolt
❑ Qty. 3
❑ 10 Nm
11 - Bolt
❑ Qty. 2
❑ 14 Nm
12 - Oil return line
13 - Bolt
❑ 10 Nm
14 - Seal
❑ Renew after removal
15 - Seal
❑ Renew after removal
16 - Bolt

346 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Qty. 3
❑ 8 Nm
17 - Air intake pipe
❑ Assembly overview - ⇒ page 377
18 - Decoupling element
19 - Seal
❑ Renew after removal
20 - Air intake pipe
❑ Plugged into turbocharger
21 - Decoupling element
22 - Seal
❑ Renew after removal
23 - Bolt
❑ 8 Nm
24 - Oil supply line
25 - Banjo bolt
❑ M10 x 1 x 23
❑ 16 Nm
26 - Seal
❑ Renew after removal
27 - Banjo bolt
❑ M12 x 1.5 x 24
❑ 30 Nm

Tightening sequence and specified torque

Sta Tightening sequence Specified torque


ge
1 Bolt -2- 20 Nm +135°
2 Nut -3- 20 Nm
3 Nut -4- 20 Nm
4 Nut -5- 20 Nm
5 Nut -6- 20 Nm

1.1.5 Assembly overview - low-pressure turbocharger

1. Turbocharger 347
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Decoupling element
2 - Air intake pipe
❑ Plugged into turbo‐
charger
3 - Decoupling element
4 - Coolant connection
5 - Low-pressure turbocharg‐
er
❑ Removing and instal‐
ling ⇒ page 354
6 - Banjo bolt
❑ M10 x 1 x 23
❑ 16 Nm
7 - Seal
❑ Renew after removal
8 - Oil supply line
9 - Seal
❑ Renew after removal
10 - Bolt
❑ M6 x 10
❑ 8 Nm
11 - Bolt
❑ Qty. 2
❑ 20 Nm
12 - Bolt
❑ 20 Nm
13 - Banjo bolt
❑ M12 x 1.5 x 24
❑ 30 Nm
14 - Seal
❑ Renew after removal
15 - Bracket
16 - Retaining ring
17 - Nut
❑ Qty. 2
❑ 8 Nm
18 - Bracket
19 - Pressure canister
❑ For wastegate
❑ Renewing ⇒ page 366
❑ Push rods are preset when delivered
❑ Fitting location ⇒ page 407
20 - Pressure canister
❑ With regulating flap potentiometer -G584-
❑ Renewing ⇒ page 366
❑ Push rods are preset when delivered

348 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Fitting location ⇒ page 407
21 - Oil return line
22 - Seal
❑ Renew after removal
23 - Bolt
❑ Qty. 2
❑ 14 Nm
24 - Bolt
❑ 10 Nm
25 - O-ring
❑ Renew after removal
❑ Moisten with oil when installing
26 - Nut
❑ Qty. 2
❑ 8 Nm
27 - Bolt
❑ Qty. 2
❑ 20 Nm
28 - Bracket
29 - Bolt
❑ Qty. 2
❑ 20 Nm

1.1.6 Assembly overview - turbocharger/exhaust manifold

1. Turbocharger 349
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Low-pressure turbocharg‐
er
❑ Assembly overview - ⇒
page 347
❑ Removing and instal‐
ling ⇒ page 354
2 - Bolt
❑ Qty. 2
❑ 20 Nm
3 - Bracket
4 - Bolt
❑ 20 Nm
5 - Bracket
6 - Bolt
❑ Qty. 2
❑ For securing emission
control module
❑ 20 Nm
7 - Bolt
❑ Qty. 3
❑ 20 Nm
8 - Seal
❑ Renew after removal
9 - Exhaust manifold
❑ Assembly overview - ⇒
page 613
❑ Tightening sequence
and specified torque ⇒
page 613
❑ Removing and instal‐
ling ⇒ page 614
10 - Nut
❑ Qty. 3
❑ 20 Nm
11 - Bolt
❑ Qty. 2
❑ 20 Nm
12 - Seal
❑ Renew after removal
13 - High-pressure turbocharger
❑ Assembly overview - ⇒ page 345
❑ Removing and installing ⇒ page 354
14 - Bolt
❑ 20 Nm
15 - Nut
❑ Qty. 4
❑ 20 Nm
16 - Bolt

350 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Qty. 3
❑ 8 Nm
17 - Air pipes
18 - Flexible joints
19 - Air pipes
20 - Oil seals
❑ Qty. 2
❑ Renew after removal
21 - Bolt
❑ Qty. 2
❑ 8 Nm
22 - Heat shield
23 - Bolt
❑ Qty. 2
❑ 20 Nm
24 - Bracket
25 - Bracket
26 - Bolt
❑ Qty. 2
❑ 20 Nm
27 - Bolt
❑ 8 Nm
28 - Seal
❑ Renew after removal

1.1.7 Assembly overview - senders and sensors on turbocharger

1. Turbocharger 351
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Lambda probe 1 before


catalytic converter -GX10-
❑ With Lambda probe -
G39-
❑ With Lambda probe
heater -Z19-.
❑ Removing and instal‐
ling ⇒ page 494
❑ 52 Nm
2 - NOx sender control unit
-GX30-
❑ Comprises NOx sender
-G295- and control unit
for NOx sender -J583-
❑ Removing and instal‐
ling ⇒ page 471
❑ 52 Nm
3 - Exhaust gas temperature
sender 2 -G448-
❑ Removing and instal‐
ling ⇒ page 584
❑ 45 Nm
4 - Exhaust gas temperature
sender 1 -G235-
❑ Removing and instal‐
ling ⇒ page 584
❑ 45 Nm
5 - Bracket
6 - Bolt
❑ 8 Nm

1.1.8 Assembly overview - oil lines on turbochargers

352 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Low-pressure turbocharg‐
er
❑ Assembly overview ⇒
page 347
2 - Seal
❑ Renew after removal
3 - Oil return line
❑ To remove, remove tur‐
bocharger
4 - Bolt
❑ Qty. 2
❑ 14 Nm
5 - Oil return line
❑ To remove, remove tur‐
bocharger
6 - O-ring
❑ Renew after removal
7 - Bolt
❑ 10 Nm
8 - High-pressure turbocharg‐
er
9 - Seal
❑ Renew after removal
10 - Oil return line
❑ To remove, remove tur‐
bocharger
11 - Bolt
❑ 10 Nm
12 - Bolt
❑ Qty. 2
❑ 14 Nm
13 - O-ring
❑ Renew after removal
14 - Seal
❑ Renew after removal
15 - Flange
❑ For connecting oil supply line to crankcase
16 - Seal
❑ Renew after removal
17 - Seal
❑ Renew after removal
18 - Bolt
❑ 10 Nm
19 - Oil supply line
❑ To remove, remove turbocharger
20 - Seal

1. Turbocharger 353
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Renew after removal
21 - Banjo bolt
❑ M12 x 1.5 x 24
❑ 30 Nm
22 - Seal
❑ Renew after removal
23 - Banjo bolt
❑ M12 x 1.5 x 24
❑ 30 Nm
24 - Oil supply line
❑ To remove, remove turbocharger
25 - Bolt
❑ 10 Nm
26 - Bolt
❑ 10 Nm
27 - Banjo bolt
❑ M10 x 1 x 23
❑ 16 Nm
28 - Seal
❑ Renew after removal
29 - Banjo bolt
❑ M10 x 1 x 23
❑ 16 Nm
30 - Seal
❑ Renew after removal

1.2 Removing and installing turbocharger


⇒ a1.2.1 nd installing high-pressure turbocharger”, page 354
⇒ a1.2.2 nd installing low-pressure turbocharger”, page 359

1.2.1 Removing and installing high-pressure


turbocharger

Caution

If a mechanical fault is discovered on the turbocharger (e.g.


a destroyed compressor impeller), it is not sufficient to just
renew the turbocharger. To avoid any subsequent damage,
the following work must be carried out:
♦ Check air filter housing, air filter element and air inlet
hoses for contamination.
♦ Check the whole charge air path and charge air cooler
for foreign objects.
♦ If foreign objects are discovered in the charge air sys‐
tem, clean the charge air path and, if necessary, renew
the charge air cooler.

Special tools and workshop equipment required

354 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Spring-type clip pliers -VAS 6362-

♦ Bit XZN 10 -T10501-

♦ Bits -T10099-

♦ Flared ring attachment AF 10 -VAS 6969-


♦ Socket Torx T 30 -T10405-

1. Turbocharger 355
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Ratchet insert 1/4" -VAS 6234-

Removing

Note

♦ Attach all heat-shielding sleeves in the same places when


installing.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Drain coolant ⇒ page 213 .


– Remove exhaust gas recirculation cooler ⇒ page 601 .
– Remove vacuum unit with regulating flap potentiometer -
G584- on low-pressure turbocharger ⇒ page 366 .
– Release and pull off connector on ABS control unit -
J104-/ABS hydraulic unit -N55- ⇒ Brake system; Rep. gr. 45;
Control unit and hydraulic unit; Removing and installing ABS
control unit J104/ABS hydraulic unit N55.
– Lay connector aside.
– Unscrew bolts -2- and -3-.

356 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove bracket -5-.


– Unscrew bolts -arrows-.
– Open clamp -8-, and position it on intake funnel of emission
control module.

– Unscrew bolts -4-.


– Unscrew bolts -6- and -7-.
– Move emission control module -1- towards right side and
place it in engine compartment.
– Pull off pipe -1-.

1. Turbocharger 357
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows- and remove pipe -2-.


– Remove oil supply line -2-. To do this, unscrew banjo bolt
-arrow B-.

– Do not open or remove heat shield on line.


– Unscrew exhaust gas temperature sender 1 -G235- on high-
pressure turbocharger ⇒ page 584 .
– Lay wiring harness to one side.
– Unscrew nuts -arrows-.

– Unscrew bolt -2-, and remove high-pressure turbocharger


-1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

358 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ Renew seals, gaskets, O-rings and self-locking nuts after


removal.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ After installing turbocharger, run engine for about 1 minute
at idling speed to ensure that oil is supplied to turbocharger.
Do not rev engine immediately.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Electrical connections and routing ⇒ Electrical system; Rep.


gr. 97; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, elec‐
tronics boxes and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Specified torques
♦ ⇒ Fig. ““Tightening sequence and specified torque”“, page
347
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ o1.1.4 verview - high-pressure turbocharger”, page 345
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o2.1 verview - charge air system”, page 377

1.2.2 Removing and installing low-pressure


turbocharger
Special tools and workshop equipment required

1. Turbocharger 359
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Socket Torx T 30 -T10405-

♦ Ratchet insert 1/4" -VAS 6234-

♦ Bit XZN 10 -T10501-

Caution

If a mechanical fault is discovered on the turbocharger (e.g.


a destroyed compressor impeller), it is not sufficient to just
renew the turbocharger. To avoid any subsequent damage,
the following work must be carried out:
♦ Check air filter housing, air filter element and air inlet
hoses for contamination.
♦ Check the whole charge air path and charge air cooler
for foreign objects.
♦ If foreign objects are discovered in the charge air sys‐
tem, clean the charge air path and, if necessary, renew
the charge air cooler.

360 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Removing

Note

♦ Attach all heat-shielding sleeves in the same places when


installing.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Remove high-pressure turbocharger ⇒ page 354 .


– Remove emission control module ⇒ page 523 .
– Unbolt control unit for NOx sender -GX30- from low-pressure
turbocharger ⇒ page 471 .
– Unscrew Lambda probe 1 before catalytic converter -GX10-
on low-pressure turbocharger ⇒ page 494 .
– Unscrew exhaust gas temperature sender 2 -G448- on low-
pressure turbocharger ⇒ page 584 .
– Unscrew bolt -arrow- on coolant pipes -1-.

– Open clips -3-, and pull off water hoses -4-.

1. Turbocharger 361
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Open clip -3- and pull off coolant hose -2- from turbocharger.

– Remove oil supply line -1-. To do this, unscrew banjo bolt


-arrow A-.

– Do not open and remove heat shield on line.


– Unscrew bolts -2- and -3- and remove oil return line -1-.

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

362 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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

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

– Unscrew nuts -arrows-.

– Remove low-pressure turbocharger together with exhaust


manifold from cylinder head.
– Guide out low-pressure turbocharger downwards together
with exhaust manifold.

1. Turbocharger 363
Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Remove low-pressure turbocharger from exhaust manifold:

– Unscrew nuts -arrows- on low-pressure turbocharger -1-.


– Unscrew bolts -arrows-.

– Remove low-pressure turbocharger -1- from exhaust mani‐


fold -2-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Make sure the rubber guard of the vacuum line is properly
seated on the heat shield of the cylinder head cover.
– When tightening, secure oil lines to prevent them from turn‐
ing.

364 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ Renew seals, gaskets, O-rings and self-locking nuts after


removal.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ After installing turbocharger, run engine for about 1 minute
at idling speed to ensure that oil is supplied to turbocharger.
Do not rev engine immediately.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Electrical connections and routing ⇒ Electrical system; Rep.


gr. 97; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, elec‐
tronics boxes and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Specified torques
Component Specified torque
Vacuum lines on turbocharger 8 Nm
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o1.1.8 verview - oil lines on turbochargers”, page 352
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ a6.2 nd installing exhaust manifold”, page 614
♦ ⇒ o1.2.2 verview - cylinder head cover with add-on parts”,
page 119
♦ ⇒ o2.1 verview - toothed belt cover”, page 138

1. Turbocharger 365
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ o3.9 verview - injector for reducing agent”, page 566


♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ o6.1 verview - exhaust manifold”, page 613
♦ ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carri‐
ers, electronics boxes; Overview of fitting locations - relay
carriers, fuse carriers, electronics boxes
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Lower suspen‐
sion link, swivel joint; Assembly overview – lower suspension
link, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 34; Bevel box; Assembly overview - bevel box
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft

1.3 Removing and installing vacuum unit


for turbocharger
⇒ a1.3.1 nd installing vacuum unit with regulating flap potentio‐
meterG584 on low-pressure turbocharger”, page 366
⇒ a1.3.2 nd installing vacuum unit for wastegate on low-pres‐
sure turbocharger”, page 369

1.3.1 Removing and installing vacuum unit


with regulating flap potentiometer -
G584- on low-pressure turbocharger
Removing
Fitting location ⇒ Item 20 (page 348) :
– Remove vacuum unit for wastegate on low-pressure turbo‐
charger ⇒ page 369 .
– Remove air filter housing and air filter bracket ⇒ page 443 .
Tiguan:

– Unscrew nuts -arrows B-.


– Remove bracket -1- from gearbox mounting -3-.
– Release and pull off coolant lines -4- from bracket -arrow A-.
– Lay coolant lines to side.

366 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Passat and Arteon:

– Unscrew nuts -arrows-.


– Remove retainer -1- from water pipe -4- and gearbox mount‐
ing -3-.
– Lay aside coolant line downwards.
– Remove air pipe ⇒ page 382 .
Continued for all vehicles:

– Release catch -arrow- and disconnect vacuum hose -1-.


– Release vacuum in brake servo by depressing brake pedal
several times.
– Pull vacuum hose -1- out of brake servo -2-.

– Remove vacuum hose.


– Pull vacuum hose -arrow- off vacuum unit -2-.

1. Turbocharger 367
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release connector -3- and pull off.


– Pull off retaining ring -arrow- for control rod -2-.

– Pull off push rod -2- from adjusting lever -3-.

Note

When removing and installing the circlip, apply as little force


as possible to the lever linkage. The turbocharger may be dam‐
aged when the circlip is pushed down, e.g. using a large screw‐
driver.

– Unscrew nuts -arrows- and pull out vacuum unit on turbo‐


charger.

– Remove vacuum unit from above between brake master cyl‐


inder and engine.
Installing
Install in reverse order of removal. While doing so, observe the
following:

368 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Compare length of control rod from old vacuum unit with that
of control rod from new vacuum unit and adjust as necessa‐
ry.
– Turn control rod of new vacuum unit until same length is
achieved.
– Tighten lock nut of control rod to 8 Nm.
– Place control rod on lever. Control rod must be parallel to
lever.
– Fit retaining ring.
– Start engine, and clear event memory ⇒ Vehicle diagnostic
tester.
– Carry out basic setting of vacuum unit.
– Follow the path below to perform basic setting:
Diagnosis-compatible systems
0001 - Engine electronics functions
0001 - Basic setting
Adaptation of turbocharger
Specified torques
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o2.1 verview - assembly mountings”, page 29
Bolts Specified torque
Retainer for coolant 20 Nm
lines on gearbox
mounting

1.3.2 Removing and installing vacuum unit


for wastegate on low-pressure turbo‐
charger
Special tools and workshop equipment required
♦ Engine support -T10533-

Removing
Fitting location ⇒ Item 19 (page 348) :

1. Turbocharger 369
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Release and pull off connector -1- for oil level and oil tem‐
perature sender -G266-.

– Release and pull off connector -2- on auxiliary pump for


heating -V488-.
– To do this, open locking device -3- by pressing in direction of
-arrow- and release connector.
– Remove pendulum support ⇒ page 39 .
– Remove propshaft from bevel box ⇒ Propshaft and rear final
drive; Rep. gr. 39; Propshaft.
– Position engine support -T10533- -A- as shown.

– Engine support -T10533/2- -B- is positioned on flat bolt con‐


necting point of engine support -T10533/1-.
– Screw in original bolt of pendulum support -1- in front threa‐
ded hole of pendulum support.
– Screw bolt M8 × 60 mm -2- with washer into left threaded
hole of noise insulation.

370 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Between high bolt connecting point and subframe, engineer


a distance of 20 mm with washers -a-.
– Tighten bolts by hand.
– Using engine support -T10533-, push engine as far forwards
as possible.
– Ensure that there is sufficient clearance to all components.
– Ensure that coolant hoses are not trapped between engine
and radiator.
– Removing and installing exhaust gas temperature sender 4
-G648- ⇒ page 595 .
– Remove exhaust gas recirculation valve 2 - GX6- ⇒ page
609 .
– Remove turbocharger 1 control unit - J724- ⇒ page 372 .
– Unscrew bolts -arrows-, and remove water pipes -1-.

– Pull vacuum hose -arrow- off vacuum unit -1-.

– Pull off circlip -arrow- on adjusting lever -4-.

1. Turbocharger 371
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull off push rod -1- from adjusting lever -4-.

Note

When removing and installing the circlip, apply as little force


as possible to the lever linkage. The turbocharger may be dam‐
aged when the circlip is pushed down, e.g. using a large screw‐
driver.

– Unscrew nuts -arrows-, and pull out vacuum unit towards


rear.

– Remove heat shield.


Installing
Install in reverse order of removal. While doing so, observe the
following:
– Compare length of control rod from old vacuum unit with that
of control rod from new vacuum unit and adjust as necessa‐
ry.
– Turn control rod of new vacuum unit until same length is
achieved.
– Tighten lock nut of control rod to 8 Nm.
– Place control rod on lever. Control rod must be parallel to
lever.
– Fit retaining ring.
– Note installation position of heat shield.
Specified torques
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o2.1 verview - assembly mountings”, page 29

1.4 Removing and installing turbocharger 1


control unit -J724-
Special tools and workshop equipment required

372 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Insert tool -T10572-

♦ Torx bit T30 -T10573-

♦ Torque wrench -V.A.G 1783-

♦ Torque wrench accessories -V.A.G 1410/1-


– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Remove exhaust gas recirculation valve 2 -GX6- ⇒ page
609 .
– Pull heat insulation sleeve off connector -2-.

1. Turbocharger 373
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -2- on turbocharger 1 control


unit -J724- -1-.
– Unscrew bolts -arrows A-, and remove heat shield -1-.

– Unclip wiring harness from heat shield -1-.


– Pull off circlip -3-.

– Pull off push rod -2- from adjusting lever on turbocharger 1


control unit -J724- -1-.

Note

When removing and installing the circlip, apply as little force


as possible to the lever linkage. The turbocharger may be dam‐
aged when the circlip is pushed down, e.g. using a large screw‐
driver.

– Unscrew bolts -3-.

374 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Renew turbocharger 1 control unit -J724- on turbocharger


-2-.
Installing

Note

Use new bolts and a new circlip from the repair kit.

– Ensure that turbocharger 1 control unit -J724- -1- is seated


correctly.

– Intermediate plate -2- must be located on guides -arrows-.


– Guides -arrows- must sit in holes on high-pressure turbo‐
charger.
– Tighten bolts -arrows A- with insert -T10572-, Torx bit T30
-T10573- and torque wrench -V.A.G 1783-.

– Set torque wrench -V.A.G 1783- to 4.2 Nm.

1. Turbocharger 375
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ It is also possible to use torque wrench accessories -V.A.G


1410/1-, Torx bit T30 -T10573- and torque wrench -V.A.G
1783-.
♦ If insert -T10572- is used for tightening, a torque of 4.2 Nm
must be set on the torque wrench.
♦ If a different tool is used, e.g. torque wrench accessories
-V.A.G 1410/1-, the values specified in the assembly over‐
view must be set.

– Start engine, and clear event memory ⇒ Vehicle diagnostic


tester.
– Carry out basic setting of vacuum unit.
– Follow the path below to perform basic setting:
Diagnosis-compatible systems
0001 - Engine electronics functions
0001 - Basic setting
Adaptation of turbocharger
Specified torque

Note

♦ If insert -T10572- is used for tightening, a torque of 4.2 Nm


must be set on the torque wrench.
♦ If a different tool is used, e.g. torque wrench accessories
-V.A.G 1410/1-, the values specified in the assembly over‐
view must be set.

♦ ⇒ o1.1 verview - turbocharger”, page 341


♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o3.1 verview - coolant pipes”, page 294

376 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Charge air system


⇒ o2.1 verview - charge air system”, page 377
⇒ a2.2 nd installing charge pressure sender G31”, page 379
⇒ a2.3 nd installing charge pressure sender 2G447”, page 379
⇒ c2.4 harge air system for leaks”, page 380
⇒ a2.5 nd installing air pipe”, page 382
⇒ c2.6 harge air cooler for leaks”, page 389

2.1 Assembly overview - charge air system

2. Charge air system 377


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bracket
2 - Bolt
❑ 20 Nm
3 - Decoupling element
4 - Air intake pipe
5 - Clip
6 - Charge pressure sender 2
-G447-
❑ Removing and instal‐
ling ⇒ page 379
7 - Bolt
❑ 8 Nm
8 - Air intake pipe
9 - Compressor bypass valve
10 - Seal
❑ Renew after removal
11 - Seal
❑ Renew after removal
12 - Bolt
❑ Qty. 2
❑ 8 Nm
13 - Air intake pipe
14 - Bolt
❑ 8 Nm
15 - Pulsation damper
❑ Removing and instal‐
ling ⇒ page 382
16 - Bolt
❑ 8 Nm
17 - Bolt
❑ Bolt is encapsulated
❑ 8 Nm
18 - Seal
❑ Renew after removal
19 - Bolt
❑ 20 Nm
20 - Charge air pressure hose
21 - Screw-type clamp
❑ 2 Nm
22 - Bolt
❑ 20 Nm
23 - Bolt
❑ 8 Nm

378 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Charge pressure sender -G31-/charge pressure sender 2 -


G447- - specified torque

1- Charge air pressure sender -G31-


2- Charge pressure sender 2 -G447-
Bolt Specified torque
Bolt -arrows- 9 Nm

2.2 Removing and installing charge pres‐


sure sender -G31-
Fitting location of charge pressure sender -G31- ⇒ page 396 :
– Remove engine cover panel ⇒ page 61 .
– Open hose clip -4- and pull off hose -5- from charge pres‐
sure sender -G31- -1-.

– Release and pull off connector -3- from charge pressure


sender -G31- -1-.
– Unscrew bolt -arrow-.
Specified torques
♦ ⇒ Fig. ““Charge pressure sender -G31-/charge pressure
sender 2 -G447- - specified torque”“, page 379

2.3 Removing and installing charge pres‐


sure sender 2 -G447-
Fitting location of charge pressure sender 2 -G447- ⇒ page
377 :
– Remove engine cover panel ⇒ page 61 .
– Open hose clip -4- and pull off hose -5- from charge pres‐
sure sender 2 -G447- -2-.

2. Charge air system 379


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -3- from charge pressure


sender 2 -G447- -2-.
– Unscrew bolt -arrow-.
Specified torques
♦ ⇒ Fig. ““Charge pressure sender -G31-/charge pressure
sender 2 -G447- - specified torque”“, page 379

2.4 Checking charge air system for leaks


Special tools and workshop equipment required
♦ Charge air system tester -V.A.G 1687-

♦ Adapter -V.A.G 1687/10-


♦ Adapter -V.A.G 1687/13-2-
Procedure
– Remove engine cover panel ⇒ page 61 .

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

380 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– If necessary, remove air filter housing ⇒ page 441 .
– Connect adapter -V.A.G 1687/10- with adapter -V.A.G
1687/13-2- to turbocharger -1-.

2 - Adapter -V.A.G 1687/13-2-


3 - Adapter -V.A.G 1687/10-
– Connect charge air system tester -V.A.G 1687- to adapter.
Prepare charge air system tester -V.A.G 1687- as follows:

2. Charge air system 381


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull pressure control valve -2- upwards, unscrew it com‐


pletely, and close valves -3- and -4-.
– Connect charge air system tester -V.A.G 1687- to com‐
pressed air -1- via commercial adapter.

Note

If there is water in the inspection glass -6-, drain it via the drain
plug.

– Open valve -3-.


– Adjust pressure to 0.5 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.
– Check charge air system for leaks:
♦ by listening
♦ by feeling
♦ Using commercially available leak detector spray
♦ Using ultrasonic tester -V.A.G 1842-

Note

♦ A small amount of air escapes through the valves into the


engine and also enters the exhaust system via the exhaust
gas recirculation cooler. Therefore a holding pressure test is
not possible.
♦ For information on how to use the ultrasonic tester -V.A.G
1842-, see the ⇒ operating instructions.
♦ Before removing the adapter, release pressure in the test
circuit by pulling off hose coupling.

Installing
Assemble in reverse order of dismantling.
Specified torques
♦ ⇒ o4.1 verview - air filter housing”, page 441

2.5 Removing and installing air pipe


Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

382 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Ratchet wrench -V.A.G 1331/1-

♦ Bit XZN 10 -T10501-

♦ Torque wrench -V.A.G 1410-

♦ Torque wrench accessories -V.A.G 1410/1-


♦ Bit XZN 10 -T10154-

2. Charge air system 383


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Socket Torx T 30 -T10405-

♦ Ratchet insert 1/4" -VAS 6234-

♦ Torque wrench -VAS 6854-

– Remove engine cover panel ⇒ page 61 .


– Remove air filter housing ⇒ page 443 .
– Remove carrier for air filter housing ⇒ page 444 .
– Press release tabs on crankcase breather hose -4-, and
remove hose from intake hose -1-.

384 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Release catch -arrow- and disconnect vacuum hose -1-.

– Release vacuum in brake servo by depressing brake pedal


several times.
– Pull vacuum hose -1- out of brake servo -2-.

– Remove vacuum hose.


– Release and pull off electrical connectors from brake fluid
level warning contact -F34- -3- and from brake light switch
-F- -1-.

– Unclip wiring harness on brake master cylinder.


– Unclip wiring harness for control unit for NOx sender -GX30-
on brake master cylinder.

2. Charge air system 385


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Tiguan:

– Remove nuts -arrows B- from gearbox mounting -3-.


– Release and pull off coolant lines -4- from bracket -arrow A-.
– Remove bracket -1- from gearbox mounting -3-.
– Lay aside coolant line downwards.
Passat and Arteon:

– Unscrew nuts -arrows-.


– Remove retainer -1- from water pipe -4- and gearbox mount‐
ing -3-.
– Lay aside coolant line downwards.
Continued for all vehicles:

– Release and pull off connector -3- from charge pressure


sender 2 -G447- -2-.
– Unscrew bolt -arrow- for charge pressure sender 2 -G447-
-2- and remove charge pressure sender.
– Unscrew bolt -2-.

386 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– To do this, push wiring harness to one side.


– Unscrew bolt -3- via the recess -arrow- behind pipe -1-.
– Swing out pulsation damper at threaded connection.
– Pull pulsation damper off intake manifold on turbocharger
-4-.
– Pull off charge air hose -1- from throttle valve.

– To do this, loosen clamp -arrow- on throttle valve housing.


– Unscrew bolts -arrows-.

– Pull off air pipe -1- from turbocharger -2-.


Installing:
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Check decoupling elements for damage.
– Degrease and clean flexible joints.
– Push charge air hose onto air pipe.

2. Charge air system 387


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Fit air pipe on turbocharger.


– Fit air pipe to bracket.
– Attach charge pressure hose -1- to throttle valve module
-GX3- and push on.

– Bring air pipe and charge pressure hose into installation


position.
– Renew seal between pulsation damper and air pipe ⇒ Item
18 (page 378) .
– Push pulsation damper -1- onto connection on turbocharger
-4-.

– Swivel pulsation damper towards flange on air pipe.


– Align components to each other.
– Start bolts -2- and -3- and screw in loosely.
– Start bolts for air pipe and screw in loosely ⇒ page 377 .
– Make sure that pipes are properly seated.
– Flange between pulsation damper -1- and air pipe must rest
flat against surface.
– Tighten bolts -2- and -3- using torque wrench -VAS 6854-,
1/4" ratchet -VAS 6234- and Torx bit T 30 -T10405-.
– Tighten bolts for air pipe -4- in the sequence shown.

388 Rep. gr.21 - Turbocharging/supercharging


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Tighten bolts -1- and -2- using torque wrench -V.A.G 1410-,
torque wrench accessories -V.A.G 1410/1- and bit XZN 10
-T10154-.
– Tighten bolt -3- using torque wrench -V.A.G 1331-, ratchet
-V.A.G 1331/1- and bit XZN 10 -T10501-.
Specified torques
Bolts Specified torque
Retainer for coolant 20 Nm
lines on gearbox
mounting
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o4.1 verview - air filter housing”, page 441

2.6 Checking charge air cooler for leaks

Note

A pressure of 0.5 bar is applied to the air side of the charge


air cooler. While so, the pressure in the cooling system is meas‐
ured.

Special tools and workshop equipment required


♦ Charge air system tester -V.A.G 1687-

♦ Adapter -V.A.G 1687/10-


♦ Adapter -V.A.G 1687/13-2-

2. Charge air system 389


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Y-branch -VAS 691 005/1-

♦ Test adapter -VAS 691 005/5-


♦ Turbocharger tester -V.A.G 1397A-

Test specification:
• Coolant temperature must be at least 40 °C.
Connecting turbocharger tester -V.A.G 1397A-:

– Screw adapter -VAS 691 005/5- onto coolant expansion


tank.
– Fit Y-branch -VAS 691 005/1- onto adapter -VAS 691
005/5-.
– Close valve -1- for connection »C«, and open valve -2- for
connection »A«.

390 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Connect hose from connection »A« of Y-branch to connec‐


tion »II« of turbocharger tester -V.A.G 1397A-.
– Set turbocharger tester -V.A.G 1397A- to switch posi‐
tion »II« (gauge pressure measurement), and switch it on.
The setting »II« must be visible.
Connecting charge air system tester -V.A.G 1687-:
– Remove engine cover panel ⇒ page 61 .

Caution

Depending on the vehicle version and country-specific mod‐


ifications, crankcase breather hoses which cannot be re‐
moved from the cylinder head cover without being damaged
may be installed. This type of crankcase breather hose must
only be disconnected at the connecting piece for the air
hose.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– If necessary, remove air filter housing ⇒ page 441 .
– Connect adapter -V.A.G 1687/10- with adapter -V.A.G
1687/13-2- to turbocharger.
– Connect charge air system tester -V.A.G 1687- to adapter.

2. Charge air system 391


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Prepare charge air system tester -V.A.G 1687- as follows:

– Pull pressure control valve -2- upwards, unscrew it com‐


pletely, and close valves -3- and -4-.
– Connect charge air system tester -V.A.G 1687- to com‐
pressed air -1- via commercial adapter.

Note

If there is water in the inspection glass -6-, drain it via the drain
plug.

– Open valve -3-.


– Adjust pressure to 0.5 bar with pressure control valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.

Note

A small amount of air escapes through the valves into the en‐
gine and also enters the exhaust system via the exhaust gas
recirculation cooler. Therefore a holding pressure test is not
possible.

392 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Reading turbocharger tester -V.A.G 1397A-:

• Observe turbocharger tester for approx. 5 minutes.


• The pressure indicated on the turbocharger tester must not
exceed 0.051 bar.
– If the pressure on the turbocharger tester continually ex‐
ceeds 0.051 bar, compressed air will escape on the intake
side into the cooling system. The charge air cooler has a
leak. Renew charge air cooler.

Note

♦ Due to reheating effects of the coolant, the pressure might


increase slightly (by 0.051 bar). This low increase in pres‐
sure, however, does not indicate a leak!
♦ When coolant cools down, a vacuum may build up. The
vacuum is indicated by a »minus« symbol on the turbocharg‐
er tester. Values preceded by a »minus« symbol do not indi‐
cate a leak!
♦ In the case of doubts, perform the test one more time. To do
so, briefly open the cut-off valve -1- to release pressure from
the cooling system. If the charge air cooler has a leak, every
test will show a continuous pressure increase.

Cleaning Y-branch -VAS 691 005/1-:

2. Charge air system 393


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

After the leakage test has been completed, the Y-branch -VAS
691 005/1- must be cleaned and any moisture which may have
entered must be removed.

– Insert cleaning nozzle -D- into hose on connection -A- of Y


junction.
– Fit adapter -VAS 691 005/5- onto hose of connection -B-.
– Fit compressed air hose to connection -C-.
– Open shut-off taps, and blow out hose for approx. 15 sec‐
onds.

394 Rep. gr.21 - Turbocharging/supercharging


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

23 – Mixture preparation - injection


1 Injection system
⇒ o1.1 verview - fuel system”, page 395
⇒ o1.2 f fitting locations - injection system”, page 396
⇒ f1.3 uel system”, page 410
⇒ f1.4 uel system for leaks”, page 410

1.1 Schematic overview - fuel system

Note

♦ Green = fuel supply line


♦ Blue = fuel return line
♦ Arrows show direction of fuel flow.

1 - Fuel filter
❑ Assembly overview
⇒ Rep. gr. 20; Fuel fil‐
ter; Assembly overview
- fuel filter
2 - High-pressure pump
❑ Assembly overview ⇒
page 488
3 - Fuel metering valve -
N290-
4 - Fuel temperature sender
-G81-
❑ Removing and instal‐
ling ⇒ page 470
5 - Fuel pressure sender -
G247-
❑ Assembly overview ⇒
page 419
6 - Fuel distributor
❑ Assembly overview ⇒
page 419
7 - Fuel pressure regulating
valve -N276-
❑ Assembly overview ⇒
page 419
8 - Pressure retention valve
9 - Injectors
❑ Assembly overview ⇒
page 417
10 - Fuel
❑ With fuel system pres‐
surisation pump -G6-
❑ Assembly overview ⇒ Rep. gr. 20; Fuel tank; Assembly overview - fuel tank

1. Injection system 395


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.2 Overview of fitting locations - injection


system
⇒ o1.2.1 f fitting locations - injection system, engine compart‐
ment”, page 396
⇒ o1.2.2 f fitting locations - injection system, engine from
above”, page 400
⇒ o1.2.3 f fitting locations - injection system, front view of en‐
gine”, page 402
⇒ o1.2.4 f fitting locations - injection system, rear view of en‐
gine”, page 405
⇒ o1.2.5 f fitting locations - injection system, engine from left”,
page 407
⇒ o1.2.6 f fitting locations - electrical connectors, Passat and
Arteon”, page 408
⇒ o1.2.7 f fitting locations - electrical connectors, Tiguan”, page
409

1.2.1 Overview of fitting locations - injection system, engine compartment

396 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Fuel pressure sender -


G247-
❑ Assembly overview ⇒
page 419
2 - Injector, cylinder 1 -N30-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
3 - Pressure differential send‐
er -G505-
❑ Installed depending on
which emission stand‐
ard the vehicle is com‐
pliant with.
❑ Assembly overview ⇒
page 584
4 - Exhaust gas pressure sen‐
sor 1 -G450-
❑ Assembly overview ⇒
page 584
5 - Injector, cylinder 2 -N31-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
6 - Injector, cylinder 3 -N32-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
7 - Injector, cylinder 4 -N33-
❑ Assembly overview ⇒
page 417
❑ Removing and installing ⇒ page 427
8 - Turbine changeover valve -N529-
❑ Connection diagram ⇒ page 412
9 - Air mass meter -G70-
❑ Assembly overview ⇒ page 441
❑ With intake air temperature sender -G42-.
10 - Exhaust gas temperature sender 1 -G235-
❑ Removing and installing ⇒ page 584
❑ Coat with high-temperature paste; high-temperature paste ⇒ Electronic Parts Catalogue.
❑ 45 Nm
11 - NOx sender control unit -GX30-
❑ Comprises NOx sender -G295- and control unit for NOx sender -J583-
❑ Removing and installing ⇒ page 471
12 - Charge pressure sender 2 -G447-
❑ Assembly overview ⇒ page 377
❑ Removing and installing ⇒ page 379
13 - Charge pressure control solenoid valve -N75-

1. Injection system 397


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ Connector for charge pressure control solenoid valve -N75-.
❑ Connection diagram ⇒ page 412
14 - Charge air pressure sender -G31-
❑ Assembly overview ⇒ page 377
15 - Engine control unit -J623-
❑ Removing and installing ⇒ page 481
16 - Fuel pressure regulating valve -N276-
❑ Assembly overview ⇒ page 419
17 - Wiring harness
❑ On top of engine
18 - Glow plug 4 -Q13-
❑ Assembly overview ⇒ page 616
19 - Glow plug 3 -Q12-
❑ Cylinder 3 combustion chamber pressure sender -G679-
❑ Assembly overview ⇒ page 616
20 - Charge air temperature sender after charge air cooler -G811-
❑ Assembly overview ⇒ page 447
21 - Charge air temperature sender before charge air cooler -G810-
❑ Assembly overview ⇒ page 447
22 - Hall sender -G40-
❑ Assembly overview ⇒ page 616
❑ Camshaft position sensor
23 - Glow plug 2 -Q11-
❑ Assembly overview ⇒ page 616
24 - Glow plug 1 -Q10-
❑ Assembly overview ⇒ page 616
25 - Fuel temperature sender -G81-
❑ In fuel supply line
❑ Removing and installing ⇒ page 470
26 - Fuel metering valve -N290-
27 - High-pressure pump
❑ Assembly overview ⇒ page 488 ⇒ page 488
28 - Coolant valve for cylinder head -N489-
❑ Fitting location ⇒ page 399

Accelerator position sender -G79- and accelerator position


sender 2 -G185-

398 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ In accelerator pedal module.


2 - Connector for accelerator pedal module

Note

The accelerator position sender -G79- and accelerator position


sender 2 -G185- are integrated in the accelerator pedal module
and cannot be renewed individually.

Fitting location of exhaust flap control unit -J883-

• In front exhaust pipe


Removing and installing ⇒ page 527
Fitting location of coolant valve for cylinder head -N489-

1. Injection system 399


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

• -Item 1- at top of coolant pump


Removing and installing ⇒ page 283

1.2.2 Overview of fitting locations - injection system, engine from above

400 Rep. gr.23 - Mixture preparation - injection


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Exhaust gas pressure sen‐


sor 1 -G450-
❑ Assembly overview ⇒
page 584
2 - Pressure differential send‐
er -G505-
❑ Assembly overview ⇒
page 584
3 - Injector, cylinder 2 -N31-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
4 - Injector, cylinder 3 -N32-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
5 - Injector, cylinder 4 -N33-
❑ Assembly overview ⇒
page 417
❑ Removing and instal‐
ling ⇒ page 427
6 - Fuel pressure regulating
valve -N276-
❑ Assembly overview ⇒
page 419
7 - Glow plug 4 -Q13-
❑ Assembly overview ⇒
page 616
8 - Glow plug 3 -Q12-
❑ With cylinder 3 com‐
bustion chamber sender -G679-
❑ Assembly overview ⇒ page 616
9 - Glow plug 2 -Q11-
❑ Assembly overview ⇒ page 616
10 - Glow plug 1 -Q10-
❑ Assembly overview ⇒ page 616
11 - Fuel temperature sender -G81-
❑ In fuel supply line
❑ Removing and installing ⇒ page 470
12 - Coolant valve for cylinder head -N489-
❑ Fitting location ⇒ page 399
13 - Fuel pressure sender -G247-
❑ Assembly overview ⇒ page 419
14 - Injector, cylinder 1 -N30-
❑ Assembly overview ⇒ page 417
❑ Removing and installing ⇒ page 427

1. Injection system 401


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.2.3 Overview of fitting locations - injection system, front view of engine


View 1:

402 Rep. gr.23 - Mixture preparation - injection


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Fuel metering valve -


N290-
❑ Assembly overview ⇒
page 488
2 - Injector for reducing agent
-N474-
❑ Assembly overview ⇒
page 566
3 - Exhaust gas recirculation
valve 1 -GX5-
❑ Assembly overview ⇒
page 598
❑ With exhaust gas recir‐
culation potentiometer -
G212-
❑ With exhaust gas recir‐
culation control motor -
V338-
4 - Charge air pressure send‐
er -G31-
❑ Assembly overview ⇒
page 377
5 - Charge pressure control
solenoid valve -N75-
❑ Connector for charge
pressure control sole‐
noid valve -N75-. ⇒
page 396
❑ Connection diagram ⇒
page 412
6 - Throttle valve module -
J338-
❑ With throttle valve po‐
tentiometer -G69-
❑ Assembly overview ⇒ page 447
7 - Oil pressure switch for reduced oil pressure -F378-
❑ Assembly overview ⇒ page 195
8 - Oil pressure switch -F1-
❑ Assembly overview ⇒ page 195
9 - Engine speed sender -G28-
❑ Assembly overview ⇒ page 616
10 - Charge air cooling pump -V188-
❑ Assembly overview ⇒ page 266
11 - Valve for oil pressure control -N428-
❑ Removing and installing ⇒ page 205
12 - Coolant temperature sender 2 -G802-
❑ Assembly overview ⇒ page 268
❑ Removing and installing ⇒ page 285
13 - Radiator outlet coolant -G62-
❑ Assembly overview ⇒ page 268
❑ Removing and installing ⇒ page 283

1. Injection system 403


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

View 2:

1 - Fuel metering valve -


N290-
❑ Assembly overview ⇒
page 488
2 - Radiator outlet coolant -
G62-
❑ Assembly overview ⇒
page 268
❑ Removing and instal‐
ling ⇒ page 283
3 - Hall sender -G40-
❑ Assembly overview ⇒
page 616
❑ Camshaft position sen‐
sor
4 - Charge air temperature
sender after charge air cooler
-G811-
❑ Assembly overview ⇒
page 447
5 - Charge air pressure send‐
er -G31-
❑ Assembly overview ⇒
page 377
6 - Exhaust gas recirculation
valve 1 -GX5-
❑ Assembly overview ⇒
page 598
❑ With exhaust gas recir‐
culation potentiometer -
G212-
❑ With exhaust gas recir‐
culation control motor -
V338-
7 - Oil pressure switch for reduced oil pressure -F378-
❑ Assembly overview ⇒ page 195
8 - Oil pressure switch -F1-
❑ Assembly overview ⇒ page 195
9 - Charge air cooling pump -V188-
❑ Assembly overview ⇒ page 266
10 - Air conditioner compressor regulating valve -N280-
❑ ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor
11 - Valve for oil pressure control -N428-
❑ Removing and installing ⇒ page 205
12 - Coolant temperature sender 2 -G802-
❑ Assembly overview ⇒ page 268
❑ Removing and installing ⇒ page 285
13 - Alternator -C-
❑ ⇒ Electrical system; Rep. gr. 27; Alternator; Exploded view - alternator

404 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.2.4 Overview of fitting locations - injection system, rear view of engine

1. Injection system 405


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Pressure canister
❑ With regulating flap po‐
tentiometer -G584-
❑ Renewing ⇒ page 366
❑ Vacuum unit for turbo‐
chargers ⇒ page 407
2 - Exhaust gas recirculation
valve 2 -GX6-
❑ With exhaust gas recir‐
culation control motor 2
-V339-.
❑ With exhaust gas recir‐
culation potentiometer
2 -G466-
❑ Assembly overview ⇒
page 598
3 - Pressure canister
❑ For wastegate
❑ Renewing ⇒ page 366
❑ Vacuum unit for turbo‐
chargers ⇒ page 407
4 - Exhaust gas pressure sen‐
sor 1 -G450-
❑ Assembly overview ⇒
page 584
5 - Exhaust gas temperature
sender 2 -G448-
❑ Assembly overview ⇒
page 494
❑ Connector for exhaust
gas temperature send‐
er 2 -G448- ⇒ page 396
6 - NOx sender control unit
-GX30-
❑ Comprises NOx sender -G295- and control unit for NOx sender -J583-
❑ Assembly overview ⇒ page 494
7 - Lambda probe -G39- with Lambda probe heater -Z19-
❑ Assembly overview ⇒ page 494
❑ Electrical connector for lambda probe -G39- ⇒ page 396
8 - Pressure differential sender -G505-
❑ Installed depending on which emission standard the vehicle is compliant with.
❑ Assembly overview ⇒ page 584
9 - Injector for reducing agent -N474-
❑ Removing and installing ⇒ page 559
10 - Exhaust gas temperature sender 3 -G495-
❑ Assembly overview ⇒ page 494
❑ Connector for exhaust gas temperature sender 3 -G495- ⇒ page 396
11 - Exhaust gas temperature sender 1 -G235-
❑ Assembly overview ⇒ page 494
12 - Auxiliary pump for heating -V488-
❑ Assembly overview ⇒ page 266

406 Rep. gr.23 - Mixture preparation - injection


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

13 - Oil level and oil temperature sender -G266-


❑ Assembly overview ⇒ page 184
14 - Exhaust gas temperature sender 4 -G648-
❑ Assembly overview ⇒ page 494
❑ Connector for exhaust gas temperature sender 4 -G648- ⇒ page 396
15 - Turbocharger 1 control unit -J724-
❑ Assembly overview ⇒ page 341
❑ With position sender for charge pressure positioner -G581-

Vacuum unit for turbochargers

1 - Vacuum unit with regulating flap potentiometer -G584-


2 - Vacuum unit for wastegate
3 - Turbocharger 1 control unit -J724-

1.2.5 Overview of fitting locations - injection system, engine from left

1. Injection system 407


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Charge air temperature


sender before charge air cool‐
er -G810-
❑ Assembly overview ⇒
page 447
2 - Throttle valve module -
J338-
❑ With throttle valve po‐
tentiometer -G69-
❑ Assembly overview ⇒
page 447
3 - Oil pressure switch for re‐
duced oil pressure -F378-
❑ Switch pressure 0.3 to
0.6 bar
❑ Insulation, green
❑ Check in Guided
fault finding ⇒ Ve‐
hicle diagnostic tester
❑ Removing and instal‐
ling ⇒ page 199
❑ 20 Nm
4 - Exhaust gas recirculation
valve 1 -GX5-
❑ Assembly overview ⇒
page 598
❑ With exhaust gas recir‐
culation potentiometer -
G212-
❑ With exhaust gas recir‐
culation control motor -
V338-
5 - Charge air pressure send‐
er -G31-
❑ Assembly overview ⇒ page 377
6 - Fuel pressure regulating valve -N276-
❑ Assembly overview ⇒ page 419
7 - Exhaust gas temperature sender 1 -G235-
❑ Removing and installing ⇒ page 584
❑ Coat with high-temperature paste; high-temperature paste ⇒ Electronic Parts Catalogue.
❑ 45 Nm
8 - Charge pressure sender 2 -G447-
❑ Assembly overview ⇒ page 377
❑ Removing and installing ⇒ page 379
9 - Charge pressure control solenoid valve -N75-
❑ Connector for charge pressure control solenoid valve -N75-.
❑ Connection diagram ⇒ page 412

1.2.6 Overview of fitting locations - electrical


connectors, Passat and Arteon
Connectors on plenum chamber bulkhead

408 Rep. gr.23 - Mixture preparation - injection


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1- Turbine changeover valve -N529-


2- Exhaust gas temperature sender 4 -G648-
3- Exhaust gas temperature sender 3 -G495-
4- Exhaust gas temperature sender 2 -G448-
5- Lambda probe 1 before catalytic converter -GX10-
6- Air mass meter -G70-

1.2.7 Overview of fitting locations - electrical


connectors, Tiguan

1- Bracket
2- Exhaust gas temperature sender 3 -G495- »brown con‐
nector«
3- Exhaust gas temperature sender 2 -G448- »black connec‐
tor«
4- Exhaust gas temperature sender 4 -G648- »beige connec‐
tor«
5- Lambda probe 1 before catalytic converter -GX10- »black
connector«
6- Turbine changeover valve -N529-

1. Injection system 409


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.3 Filling/bleeding fuel system

Caution

The high-pressure pump has very close tolerances and must


not be allowed to run without fuel. To prevent this and to ena‐
ble the engine to start quickly after parts have been renewed,
it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump have been removed or re‐
newed, the fuel system must be filled and bled before
the engine is started for the first time.

Special tools and workshop equipment required


♦ Vehicle diagnostic tester
Proceed as follows to fill high-pressure pump with fuel.
• Vehicle must have fuel.
– Connect vehicle diagnostic tester.
– Switch on ignition and select the following menu options on
vehicle diagnostic tester:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Activating fuel pump
♦ Bleeding fuel system
• The fuel pump starts up.
• The fuel pump must run for approx. 2 … 3 minutes to ensure
that the high-pressure pump is filled with a sufficient amount
of fuel.
– After the fuel system has been filled, start the engine.
– Allow engine to run for a few minutes at a moderate speed.
Then, switch it off again.
– Check fuel system for leaks.
– Erase entry in event memory using vehicle diagnostic tester.
– Then road test the vehicle, accelerating to full throttle at
least once.
– Then, check the high-pressure system for leaks again.

Note

If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch off engine
and clear event memory. Then continue with a road test.

– Erase entry in event memory using vehicle diagnostic tester.

1.4 Checking fuel system for leaks


– Start engine and run at idling speed for a few minutes.
– Do not depress accelerator pedal while doing so, and switch
engine off again. The fuel system will be bled automatically.
– Check the entire fuel system for leaks.

410 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If leaks are found although the connections have been tight‐


ened to the correct torque, the relevant component must be
renewed.
– Then road test the vehicle, accelerating to full throttle at
least once.
– Then, check the high-pressure system for leaks again.

1. Injection system 411


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2 Vacuum system
⇒ d2.1 iagram - vacuum system”, page 412
⇒ v2.2 acuum system”, page 415

2.1 Connection diagram - vacuum system


⇒ d2.1.1 iagram - vacuum system”, page 412
⇒ o2.1.2 f fitting locations - vacuum system”, page 414

2.1.1 Connection diagram - vacuum system

412 Rep. gr.23 - Mixture preparation - injection


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1 - Turbine changeover valve


-N529-
2 - Vacuum unit with regulat‐
ing flap potentiometer -G584-
3 - Vacuum unit for wastegate
4 - Air filter housing
5 - Charge pressure control
solenoid valve -N75-
6 - Connection
7 - Bolt
❑ 8 Nm
8 - Crankcase
❑ Assembly overview ⇒
page 62
9 - Vacuum reservoir
❑ Fitting location ⇒ page
119
10 - Turbocharger
❑ Assembly overview ⇒
page 341
❑ Removing and instal‐
ling ⇒ page 354
A - Vacuum line
❑ Between -1- and -2-
B - Vacuum line
❑ Between -1- and -9-
C - Vacuum line
❑ Between -3- and -5-
D - Vacuum line
❑ Between -1- and -4-
E - Vacuum line
❑ Between -5- and -9-
F - Vacuum line
❑ Between -7- and -9-
❑ Fitting position ⇒ page 413
❑ To remove, remove from lower part of intake manifold ⇒ page 450
G - Vacuum line
❑ Between -4- and -5-

Installation position of vacuum line

2. Vacuum system 413


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Pfeile A - Bolt, 8 Nm
Pfeil B - Bracket
To remove, remove from lower part -1- of intake manifold ⇒
page 450 :

2.1.2 Overview of fitting locations - vacuum system

414 Rep. gr.23 - Mixture preparation - injection


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1 - Vacuum line
❑ Connected to crank‐
case
❑ with non-return valve in
connection to vacuum
pump
2 - Control pipe for vacuum
❑ From charge pressure
control solenoid valve -
N75-
3 - Vacuum hose
❑ From vacuum line to
accumulator
4 - Pressure accumulator
5 - Turbine changeover valve
-N529-
6 - To brake servo
7 - Vacuum line
❑ Connected to brake
servo
8 - Non-return valve
❑ Observe installation po‐
sition
9 - Charge pressure control
solenoid valve -N75-
10 - To vacuum pump
❑ In oil pump ⇒ page 184
11 - Pressure canister
❑ With regulating flap po‐
tentiometer -G584-
❑ Renewing ⇒ page 366
❑ Vacuum unit for turbochargers ⇒ page 407
12 - Pressure canister
❑ For wastegate
❑ Renewing ⇒ page 366
❑ Vacuum unit for turbochargers ⇒ page 407
13 - Control pipe for vacuum
❑ From charge pressure control solenoid valve -N75- to vacuum unit ⇒ Item 11 (page 415)
14 - Control pipe for vacuum
❑ To vacuum line ⇒ Item 1 (page 415)

2.2 Checking vacuum system


Special tools and workshop equipment required

2. Vacuum system 415


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♦ Hand operated vacuum pump -VAS 6213-

Procedure
– Check all vacuum lines throughout entire vacuum system
for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid
valve to relevant component.
– If an entry is stored in the event memory, check all vac‐
uum lines leading to the corresponding component and also
check the remaining vacuum lines leading to other compo‐
nents.
– If vacuum cannot be built-up using hand vacuum pump -VAS
6213- or vacuum immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.

416 Rep. gr.23 - Mixture preparation - injection


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3 Injectors/high-pressure accumulator
(rail)
⇒ o3.1 verview - injectors”, page 417
⇒ o3.2 verview - fuel rail”, page 419
⇒ c3.3 orrection values for injectors”, page 421
⇒ i3.4 njectors”, page 422
⇒ r3.5 eturn flow rate of injectors with engine running”, page
422
⇒ r3.6 eturn flow rate of injectors at starter speed”, page 425
⇒ a3.7 nd installing injectors”, page 427
⇒ a3.8 nd installing high-pressure lines”, page 431
⇒ a3.9 nd installing fuel rail”, page 437

3.1 Assembly overview - injectors

3. Injectors/high-pressure accumulator (rail) 417


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1 - Injector
❑ If they are to be re‐
installed, the injectors
and high-pressure lines
must always be rein‐
stalled on the same cyl‐
inder.
❑ Removing and instal‐
ling ⇒ page 427
2 - Fuel return line
❑ To fuel filter
❑ Must not be kinked,
damaged or blocked.
❑ Do not dismantle.
❑ Fill and bleed fuel sys‐
tem after renewing ⇒
page 410
3 - O-ring
❑ Renew after removal
4 - Bolt
❑ Renew after removal
❑ 8 Nm +270°
5 - Clamping piece

Cau‐
tion
Risk of damage to en‐
gine.
When
♦ installing a new
base engine, it is com‐
pulsory to fix and tight‐
en the clamping pieces
of the injectors to the
specified torque after
installing the high-pres‐
sure lines ⇒ Item 4
(page 418) . Clamp‐
ing jaws are only
secured »hand-tight« for
setting the injectors
while installing high-
pressure lines.

❑ Fitting position ⇒ page 419


6 - Grommet
❑ In cylinder head cover
❑ Renew if damaged
7 - Seal
❑ In cylinder head cover
❑ Renew after removal ⇒ page 129
8 - Copper washer
❑ Renew after removal
9 - O-ring
❑ Renew after removal
10 - High-pressure line

418 Rep. gr.23 - Mixture preparation - injection


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❑ Between fuel rail and injectors
❑ Observe all instructions for installing high-pressure pipes ⇒ page 432
❑ Install so that component is not under tension
❑ Install vibration damper ⇒ page 436 .
❑ 15 Nm +60°

Clamping piece installation position

• One clamping piece encompasses 2 injectors each.


• The thick part -1- of the clamping piece points upwards.
• There is a spherical recess for bolt -2- on the upper side.

3.2 Assembly overview - fuel rail

3. Injectors/high-pressure accumulator (rail) 419


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1 - High-pressure line
❑ Between fuel rail and
injectors
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 432
❑ 15 Nm +60°
2 - High-pressure accumula‐
tor (rail)
❑ Removing and instal‐
ling ⇒ page 437
3 - Bolt
❑ 20 Nm
4 - Seal
❑ Renew after removal
5 - O-ring
❑ Renew after removal
6 - Fuel pressure regulating
valve -N276-
❑ Removing and instal‐
ling ⇒ page 459
❑ After renewing, readapt
learnt values using ve‐
hicle diagnostic tester.
❑ 100 Nm
7 - Clip
8 - High-pressure line
❑ Between high-pressure
pump and fuel rail
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 432
❑ 15 Nm +60°
9 - Fuel return hose
10 - Clip
11 - Fuel return line
12 - Bolt
❑ 8 Nm
13 - Bolt
❑ 8 Nm
14 - High-pressure line
❑ Between high-pressure pump and fuel rail
❑ Observe all instructions for installing high-pressure pipes ⇒ page 432
❑ 15 Nm +60°
15 - Fuel pressure sender -G247-
❑ Removing and installing ⇒ page 463
❑ Can be re-used ⇒ page 464
❑ 100 Nm
16 - Seal

420 Rep. gr.23 - Mixture preparation - injection


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❑ Renew after removal

3.3 Adapting correction values for injectors


♦ “Injector delivery calibration (IMA)” serves to correct the in‐
jection rate for each cylinder individually across the entire
ignition map range.

♦ The 7-digit adaption values are marked on each injector.


The marked values may consist of letters and/or numbers.
♦ Illustration shows style of writing for adaptation value on
injectors.
Top view of injector

1- Adaption value (checksum; details in illustration are only


an example)
♦ After renewing an injector, the adaptation value must be
written into the engine control unit.
♦ After renewing the engine control unit, the “adaptation val‐
ues for the injectors” must be transferred to the new engine
control unit.
♦ Also check that the “injector delivery calibration values” are
correctly entered for all the other injectors. Do not attempt to
re-enter these values if the correct values are already stored
in the engine control unit.

3. Injectors/high-pressure accumulator (rail) 421


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♦ The adaption procedure is described in the “Guided fault


finding”. (The procedure is also described under “Guided
functions”). Use vehicle diagnostic tester for this.

3.4 Testing injectors


There are 3 different ways of testing the injectors.
♦ ⇒ c3.3 orrection values for injectors”, page 421
♦ ⇒ r3.5 eturn flow rate of injectors with engine running”, page
422
♦ ⇒ r3.6 eturn flow rate of injectors at starter speed”, page 425

3.5 Checking return flow rate of injectors


with engine running
A - Checking return flow rate of all injectors
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Return flow meter -VAS 6684-

♦ Return flow meter -VAS 6684/2-


♦ Measuring container, fuel-resistant
Procedure

Note

Each injector normally has a relatively low return flow rate. If the
return flow rate of one injector is relatively high (compared to
those of the other injectors), that injector is probably defective.

– Observe rules for cleanliness ⇒ page 7 .


– Remove engine cover panel ⇒ page 61 .
– Remove noise insulation.

422 Rep. gr.23 - Mixture preparation - injection


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Cylinders 3 and 4:

– Open heat insulation sleeve -5-.


– Unscrew nut -arrow B-.
– Unscrew bolt -arrow A-.
– Lay vacuum reservoir -1- with lines connected to one side.
Continued for all cylinders:
– Open heat insulation sleeve -4-.
– Release and pull off connectors -3-.
– Lay wiring harness to one side.
Cylinders 1 and 2:
– Unscrew bolts -arrow C-.
– Lay sender with pressure differential lines connected to one
side.
Continued for all cylinders:
– Clean all return line connections (e.g. with commercially
available cold cleaning solvent) before opening them.
– Dry all cleaned parts.
– Disconnect hose connection -2- at fuel return line.

– Seal open return connection with a blanking plug -1-.


– Hold fuel return hose -2- (added an extension to it if neces‐
sary) in measuring vessel to measure total return flow.
– Start engine and run it at idling speed for 2 minutes.
• Specified amount in 2 minutes: 0 ml to 50 ml

3. Injectors/high-pressure accumulator (rail) 423


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– If specification is achieved, increase engine speed to be‐


tween 2,000 and 2,500 rpm for approx. 2 minutes, and
check return flow rate again.
• Specified amount in 2 minutes: less than 250 ml
If more fuel is returned than the specified amount, then at least
one injector is defective. Checking return flow rate of each indi‐
vidual injector.
B - Checking return flow rate of individual injectors
– Observe rules for cleanliness ⇒ page 7 .
– Clean all return line connections (e.g. with standard com‐
mercially available cold cleaning solvent) before opening
them.
– Dry all cleaned parts.
– Clamp off fuel return hose -arrow- using hose clamp up to
25 mm -3094-.

– Pull fuel return line connections off the injectors to be re‐


moved. To do this, push down connection at tabs and pull up
centre piece to release.

Note

Adhere strictly to rules of cleanliness. No dirt must be allowed to


get into the disconnected fuel return lines or the open connec‐
tions on the injectors.

– Fit adapter C7 firmly onto return line connections of all 4


injectors.
– Connect hoses of return flow meter -VAS 6684- to adapters.
– Start engine, and run it at idling speed for several minutes.

424 Rep. gr.23 - Mixture preparation - injection


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Caution

Risk of damage to injectors after return lines have been


pulled off.
♦ Do NOT press the accelerator during this test; the en‐
gine must only run at idling speed.

– When the engine is at operating temperature and running


at idling speed, the return flow rates at each of the 4 return
lines must not differ by more than a small amount (example
-1-).
– If one injector has a significantly higher return flow rate than
the others (example -2-), it must be renewed ⇒ page 427 .

Installing fuel return lines


– Carefully press connections of return lines onto injectors.
The catch should engage audibly. Then press release pin
down carefully.
– Fit engine cover panel ⇒ page 61 .
– Checking fuel system for leaks ⇒ page 410 .

3.6 Checking return flow rate of injectors at


starter speed

Note

If the engine cannot be started, the return flow rate of the injec‐
tors can also be checked at starter motor speed.

Special tools and workshop equipment required


♦ Return flow meter -VAS 6684-

3. Injectors/high-pressure accumulator (rail) 425


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♦ Return flow meter -VAS 6684/2-


Procedure

Note

Each injector normally has a relatively low return flow rate. If the
return flow rate of one injector is relatively high (compared to
those of the other injectors), that injector is probably defective.

– Remove engine cover panel ⇒ page 61 .


– Remove noise insulation.
– Observe rules for cleanliness ⇒ page 7 .
Cylinders 3 and 4:

– Open heat insulation sleeve -5-.


– Unscrew nut -arrow B-.
– Unscrew bolt -arrow A-.
– Lay vacuum reservoir -1- with lines connected to one side.
Continued for all cylinders:
– Open heat insulation sleeve -4-.
– Release and pull off connectors -3-.
– Lay wiring harness to one side.
Cylinders 1 and 2:
– Unscrew bolts -arrow C-.
– Lay sender with pressure differential lines connected to one
side.
Continued for all cylinders:
– Clean all return line connections (e.g. with commercially
available cold cleaning solvent) before opening them.
– Dry all cleaned parts.
– Pull fuel return line connections off the injectors to be re‐
moved. To do this, push down connection at tabs and pull up
centre piece to release.

426 Rep. gr.23 - Mixture preparation - injection


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– Pull return line connections off injectors. To do this, pull tabs


upwards -arrows-.

Note

Adhere strictly to rules of cleanliness. No dirt must be allowed to


get into the disconnected fuel return lines or the open connec‐
tions on the injectors.

– Fit adapter C7 firmly onto return line connections of all 4


injectors.
– Connect hoses of return flow meter -VAS 6684- to adapters.
– Activate starter 3 times (pausing for around 20 seconds after
each starting attempt to ensure that starter does not over‐
heat).
• Return flow rate specification: 0 ml
– If fuel escapes from an injector, that injector has to be re‐
newed.
– Connect connector of fuel pressure regulating valve -N276-.
Installing fuel return lines
– Press return line connections onto injectors until they en‐
gage audibly.
– Then press down tabs on both sides.
– Checking fuel system for leaks ⇒ page 410 .
– Fit engine cover panel ⇒ page 61 .
– Erase entry in event memory using vehicle diagnostic tester.

3.7 Removing and installing injectors


Special tools and workshop equipment required

3. Injectors/high-pressure accumulator (rail) 427


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♦ Puller -T10055-

♦ Puller -T10055/1-
♦ Assembly sleeve -T10377-

Removing
– Remove engine cover panel ⇒ page 61 .
– Remove noise insulation on cylinder head cover.
– Remove high-pressure lines ⇒ page 432 .
– Pull fuel return line connections off the injectors to be re‐
moved. To do this, push connection at tabs downwards light‐
ly and hold in this position. Pull upwards to release centre
piece -arrow-.

Note

One clamping piece always secures two injectors and can only
be removed if both injectors are »pulled«.

– Unscrew bolt for clamping piece ⇒ Item 4 (page 418) .

428 Rep. gr.23 - Mixture preparation - injection


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• Sequence for removing injectors: First remove injector for


cylinder “2”, then for cylinder “1” or cylinder “4” and then for
cylinder “3”.
– Fit puller -T10055- with adapter -T10055/1- as shown in il‐
lustration, and pull out injectors upwards.

– Remove clamping piece before removing injectors.

Note

To avoid damaging the sealing lip, rotate the injector while pull‐
ing it out.

– Place removed injectors on a clean cloth.


Installing

Caution

Danger of damage to sealing surface of injector.


♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector shaft in the cylinder head with
cleaning set -VAS 6811-. Refer to ⇒ operating manual
for information on how to use it.

Installing new injectors


When a fitting a new injector, the following must be replaced:
♦ Copper seal
♦ O-ring for shaft of injector
♦ O-ring for connection of fuel return line
– Note installation position of clamping pieces ⇒ page 419 .
– Observe all instructions for installing high-pressure pipes ⇒
page 432 .
Installing used injectors
When a used injector is re-fitted, the following must be re‐
placed:

3. Injectors/high-pressure accumulator (rail) 429


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♦ Copper seal
♦ O-ring for shaft of injector
♦ O-ring for connection of fuel return line
– Spray tip of injector with a rust removal spray. Wait approx.
5 minutes and wipe off soot and oil particles with a cloth.
– To remove the old copper seal from the injector, clamp the
seal carefully in a vice Clamp sufficiently so that copper seal
is just held between the jaws without turning.
– Then carefully pull and twist the injector out of the copper
seal by hand.
– Remove deposits under copper seal.
– Renew seal for injector.

– Use assembly sleeve -T10377- to do this.


Continuation for used and new injectors
– Coat injector O-rings with assembly oil, engine oil or diesel
fuel.
– Install injectors.
– Initially, tighten union nuts of high-pressure lines hand-tight.
Check they are seated without stress.
After renewing one or more injectors:
♦ Write adapted correction values for new injectors into engine
control unit ⇒ page 421 .
♦ Reset learnt values of fuel pressure regulating valve -N276-.
♦ 01 - Engine electronics
♦ 01 - Engine electronics functions
♦ 01 - Reset adaptation values of engine ctrl. mod-
ule
♦ Selection: Reset learnt values of dosing unit and
pressure regulating valve
– Fill/bleed fuel system ⇒ page 410 .
– Fit engine cover panel ⇒ page 61 .
Specified torques
• ⇒ o3.1 verview - injectors”, page 417
• ⇒ o3.2 verview - fuel rail”, page 419

430 Rep. gr.23 - Mixture preparation - injection


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3.8 Removing and installing high-pressure


lines
⇒ h3.8.1 igh-pressure pipe between fuel rail and high-pressure
pump”, page 431
⇒ a3.8.2 nd installing high-pressure line between fuel rail and
injectors”, page 432

3.8.1 Removing high-pressure pipe between


fuel rail and high-pressure pump
Removing
– Remove engine cover panel ⇒ page 61 .
– Unscrew bolts -2-, and push water line -1- to one side.

– Clean fuel line and head of line using cold cleaning solvent
and dry using compressed air.
– Unscrew bolt -6-.

– Unscrew union nuts -arrows- on fuel rail -2- and high-pres‐


sure pump -4-.
– Remove high-pressure lines -1- and -5-.
Installing
– Fit vibration dampers -3- to high-pressure lines as shown in
illustration.

3. Injectors/high-pressure accumulator (rail) 431


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Specified torques
♦ ⇒ o3.2 verview - fuel rail”, page 419
♦ ⇒ o8.1 verview - high-pressure pump”, page 488

3.8.2 Removing and installing high-pressure


line between fuel rail and injectors
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Tool insert, 17 mm -V.A.G 1331/6-

♦ Socket -T40055-

432 Rep. gr.23 - Mixture preparation - injection


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♦ Engine bung set -VAS 6122-

Removing

Note

♦ Clean fuel line and head of line using cold cleaning solvent
and dry it using compressed air prior to removing.
♦ Observe cylinder-specific markings if reusing high-pressure
lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seal of respective high-pressure line for defor‐
mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer be used.

Caution

Danger of functional impairment due to contamination/soiling


Risk of high-pressure pipe breaking if it is under tension.
♦ To ensure the injector lines are fitted free of stress, loos‐
en fuel rail and, if necessary, move it slightly. The lines
must never be bent or tensioned.

– Use a vacuum-type cleaner to remove dirt from taper seat


on high-pressure accumulator.
High-pressure line for cylinders 3 and 4:

– Open heat insulation sleeve -5-.

3. Injectors/high-pressure accumulator (rail) 433


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– Unscrew nut -arrow B-.


– Unscrew bolt -arrow A-.
– Lay vacuum reservoir -1- with lines connected to one side.
Continued for all cylinders:
– Open heat insulation sleeve -4-.
– Release and pull off connectors -3-.
– Lay wiring harness to one side.
High-pressure line for cylinders 1 and 2:
– Unscrew bolts -arrow C-.
– Lay sender with pressure differential lines connected to one
side.
Continued for all cylinders:
– Pull release tabs upwards -arrow-, and pull return line con‐
nections off injectors.

– Release and pull off connectors -arrows- on injectors.

– Release and pull off connector -arrow- on fuel pressure


sender -G247-.

434 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip wiring duct -2-, and remove it.

– Move wiring harness aside.


– Unscrew union nuts of high-pressure lines on injectors using
socket -T40055-.

– Unscrew union nuts of high-pressure lines on fuel rail using


open end spanner insert, AF 17 mm -V.A.G 1331/6-.
– Unscrew union nuts -arrows- on corresponding high-pres‐
sure lines, and remove corresponding high-pressure lines.

3. Injectors/high-pressure accumulator (rail) 435


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Seal all open lines and connections with clean dummy plugs.
Installation
– Tighten high-pressure union nuts hand-tight, check lines are
free of stress when doing this.
– Screw on union nuts of high-pressure lines on injectors us‐
ing socket -T40055-.

– Screw on union nuts of high-pressure lines on fuel rail using


open end spanner insert, AF 17 mm -V.A.G 1331/6-.
– Fit vibration dampers -2- to high-pressure lines as shown in
illustration ⇒ page 436 .
Vibration damper positions

– Checking fuel system for leaks ⇒ page 410 .


– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o3.1 verview - injectors”, page 417
♦ ⇒ o3.2 verview - fuel rail”, page 419

436 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ o1.2.2 verview - cylinder head cover with add-on parts”,


page 119
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584

3.9 Removing and installing fuel rail


Removing
– Remove high-pressure pipe between fuel rail and high-pres‐
sure pump ⇒ page 431 .
– Release and pull off connector -1- on fuel temperature send‐
er -G81-.

– Release and pull off connector -2- on fuel pressure regulat‐


ing valve -N276-.

– Release and pull off connector -arrow- on fuel pressure


sender -G247-.

– Release and pull off connector -1- at charge air temperature


sender after charge air cooler -G811-.

3. Injectors/high-pressure accumulator (rail) 437


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– Release and pull off connector -3- for coolant pump.

– Open heat insulation sleeve -1-.

– Release and pull off electrical connectors -2- and -5-.


– Lay wiring harness to one side.
– Release and pull off connector -2- on Hall sender -G40-.

438 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connectors -arrows- on injectors.

– Pull off connectors on glow plugs.

– Open retaining clips -arrows-.

– Move wiring harness aside.


– Unclip wiring duct -2-, and remove it.
– Release hose clip -4- and detach fuel return hose.

3. Injectors/high-pressure accumulator (rail) 439


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– Remove high-pressure line -2- and set it down on a clean


cloth ⇒ page 432 .
– Remove bolts -arrows- and detach high-pressure reservoir.
Installing
Install in reverse order of removal, observing the following:
– Observe all instructions for installing high-pressure pipes ⇒
page 432 .
Specified torques
♦ ⇒ o3.1 verview - injectors”, page 417
♦ ⇒ o3.2 verview - fuel rail”, page 419
♦ ⇒ o8.1 verview - high-pressure pump”, page 488

440 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

4 Air filter
⇒ o4.1 verview - air filter housing”, page 441
⇒ a4.2 nd installing air filter housing”, page 443

4.1 Assembly overview - air filter housing

4. Air filter 441


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1 - Clip
❑ Specified torque ⇒
page 443
2 - Intake hose
❑ Fitting position ⇒ page
445
3 - Clip
❑ Specified torque ⇒
page 443
4 - Bolt
❑ Qty. 2
❑ For connection
❑ 1.5 Nm
5 - Air mass meter -G70-
❑ Removing and instal‐
ling ⇒ page 464
6 - Seal
7 - Air filter upper part
❑ Check for cleanliness
8 - Bolt
9 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance
tables
❑ Removing and instal‐
ling ⇒ Maintenance;
Booklet
10 - Air filter lower part
❑ Remove dirt, leaves and salt residues
11 - Seal
12 - Water drain hose
❑ With valve
❑ Check for cleanliness, and clean as necessary
❑ Fitting position ⇒ page 445
13 - Bolt
❑ 2 Nm
14 - Lower part of air duct
15 - Upper part of air duct
16 - Carrier for air filter housing
❑ Removing and installing ⇒ page 444
17 - Bolt
❑ 8 Nm
18 - Intake hose
❑ For hot air intake.

442 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installing air ducts with screw-type clips

Note

♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ In order to be able to securely attach the air hoses on their
connections, the worm screws of the used hose clips have to
be sprayed with penetrating spray before installing.

Specified torques
Screw-type clips Specified torque
1st hose clip -a- = 5.5 Nm
13 mm wide
2nd hose clip -b- 3 Nm
= 9 mm wide

4.2 Removing and installing air filter hous‐


ing
Remove carrier for air filter housing ⇒ page 444 :
Remove air filter housing ⇒ page 444 :
Remove air duct:

– Unscrew bolts -3-.


– Pull air duct towards rear off lock carrier.
– Push air filter housing backwards.
– Guide out air duct on lock carrier upwards.

4. Air filter 443


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– Pull air duct -1- off air filter -2- on connection -arrow-.
Removing air filter housing:

– Remove air duct ⇒ page 443 .


– Release and pull off connector -3- on air mass meter -G70-.
– Loosen screw-type clip -4-.
– Remove air intake hose on air mass meter -G70- -2-.
– Pull off bracket -6-.
– Pull air filter housing -1- evenly upwards on mountings
-arrows-.
– If fitted, pull off hot air intake -5-.
Remove carrier for air filter housing:

– Remove air filter housing ⇒ page 444 .


– Unscrew bolts -2-.
– Push control unit for NOx sender -GX30- aside and remove
carrier -1-.

444 Rep. gr.23 - Mixture preparation - injection


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Installing
Install in reverse order of removal. Observe the following:

Note

♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Use a silicone-free lubricant to install the air hose.
♦ Secure hose connections with hose clips in such a way that
factory standard is restored ⇒ Electronic parts catalogue

– Disconnect water drain hose -arrow-.

– Clean dirt and leaves out of connection on air cleaner (bot‐


tom section) and hose.
– Note installation position of water drain hose.
♦ There are arrows on the water drain hose and on the con‐
nection on the air filter housing.
♦ The two arrows must be aligned when installing.
– When fitting intake hose -1- on air filter housing -2-, pay
attention to installation markings -arrows-.

– Make sure that clamps -3- are properly seated.


– Observe installation position of control unit for NOx sender
-GX30- ⇒ page 473 .
– Fit air filter housing on carrier -1- and press it onto bracket
-arrow- until it engages audibly.

4. Air filter 445


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– Use water as a lubricant.


– Press air cleaner housing on again and then pull to check
that housing is correctly engaged.
Specified torques
♦ ⇒ o4.1 verview - air filter housing”, page 441

446 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

5 Intake manifold
⇒ o5.1 verview – intake manifold”, page 447
⇒ a5.2 nd installing intake manifold”, page 450
⇒ a5.3 nd installing throttle valve moduleJ338”, page 456

5.1 Assembly overview – intake manifold

5. Intake manifold 447


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Intake manifold with


charge air cooler
❑ Intake manifold and
charge air cooler are
combined as one unit
❑ Removing and instal‐
ling ⇒ page 450
❑ Check for leaks ⇒ page
389
2 - Seal
❑ Renew after removal
3 - Charge air temperature
sender after charge air cooler
-G811-
❑ Removing and instal‐
ling ⇒ page 469
❑ 22 Nm
4 - Coolant hose
5 - Clip
6 - Seal
❑ Renew after removal
7 - Coolant hose
8 - Clip
9 - Bolt
❑ 9 Nm
10 - Charge air temperature
sender before charge air cool‐
er -G810-
❑ Removing and instal‐
ling ⇒ page 469
❑ 22 Nm
11 - Clip
12 - Seal
❑ Renew after removal
13 - Throttle valve module -J338-
❑ With throttle valve potentiometer -G69-
❑ Removing and installing ⇒ page 456
14 - Clip
15 - Charge air pressure sender -G31-
❑ With hose
16 - Bolt
❑ 10 Nm
17 - Clip
18 - Bolt
❑ 8 Nm
19 - Seal
❑ Renew after removal
20 - Bracket

448 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ For throttle valve module -J338-
21 - Clip
22 - Charge air pressure hose
23 - Clip
24 - Bolt
❑ Specified torque and tightening sequence: ⇒ page 450
25 - Nut
❑ 10 Nm
26 - Centre hex stud
❑ Specified torque and tightening sequence: ⇒ page 450
27 - Union
❑ For throttle valve module -J338-
28 - Seal
❑ Renew after removal
29 - Bolt
❑ Specified torque and tightening sequence: ⇒ page 450
30 - Bracket
❑ For intake manifold
31 - Bolt
❑ 8 Nm
32 - Dowel pin
33 - Bolt

Differences when tightening intake manifold

♦ I = intake manifold without »support lugs«: turning further


angle as per stage 3.
♦ I = intake manifold with »support lugs« -arrow-: do not tight‐
en with turning further angle.

5. Intake manifold 449


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Stag Bolts Specified torque


e
1 -1 to 10- Screw in by hand as far as stop
2 -1 to 10- Tighten to 20 Nm
Following step is only applicable for intake manifolds with‐
out »support lugs«!
3 -1 to 10- Turn 90° further
Bracket for intake manifold and bracket for throttle valve module
- specified torque and tightening sequence

– Tighten bolts in stages:

Caution

When installing brackets for intake manifold and throttle


valve module, always ensure the brackets are free of tension
and not installed at an angle.

Stag Bolts/nut Specified torque


e
1 -2, 3, 4, 7- Screw in as far as stop and tighten
by hand.
2 -2, 3, 4, 7- 20 Nm
3 -5- 10 Nm
4 -1- 10 Nm

5.2 Removing and installing intake mani‐


fold

Note

Intake manifold and charge air cooler are combined as one unit.

Special tools and workshop equipment required

450 Rep. gr.23 - Mixture preparation - injection


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♦ Spring-type clip pliers -VAS 6362-

♦ Bit XZN 10 -T10501-

♦ Protective mat -VAS 531003-


Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct and air filter ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

– Release and unplug electrical connector -4-.

5. Intake manifold 451


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– Release hose clips -1- and -2-, and remove fuel hoses.
– Remove bolts -3- and move fuel lines to rear.
– Release and pull off connectors -1- and -3-.

– Unscrew bolt -3-.

– Remove bracket with charge pressure sender.


– Remove high-pressure pipe between fuel rail and high-pres‐
sure pump ⇒ page 431 .
– Remove coolant pipe (top front) ⇒ page 298 .
– Remove front coolant connection ⇒ page 301 .
– Remove front right coolant pipe ⇒ page 303 .
– Remove front coolant pipe ⇒ page 299 .
– Remove throttle valve module -J338- ⇒ page 456 .
– Remove exhaust gas recirculation valve 1 -GX5- ⇒ page
607 .
– Release connector -2- and pull off.

452 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Open clips, and pull coolant hoses -arrows- off coolant pipe
-1-.

– Unscrew bolt -2-.


– Release retaining clip -3- in -direction of arrow-.

Note

Installation position of retaining clips varies. To release, move in


opposite direction accordingly.

– Pull off coolant pipe -2- from intake manifold -1- and push to
one side.
– Loosen clamps -arrow-.

5. Intake manifold 453


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull off water hoses -2- on intake manifold -1-.


– Remove bolt -1- for dipstick guide tube.

– Unscrew bolt for oil dipstick guide tube at bottom on crank‐


case ⇒ Item 21 (page 186) .
– Unscrew bolt on intake manifold for left bracket ⇒ page 447 .
– Unscrew nut -5- and remove bracket -6- from centre hex
stud -4-.
– Unscrew bolts -2- to -4- and -7-.
– Remove bracket for intake manifold.
– Move clear wiring harness to engine control unit on engine,
and push it to one side.
– Unscrew bolts using bit XZN 10 -T10501-.

454 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Guide out intake manifold with charge air cooler, and re‐
move it.
Installing
Continue installation in reverse order of removal. During this
procedure, observe the following:
– Fit new gasket onto dowel pins on cylinder head. Renew
gaskets after each removal.

Caution

Do not damage sealing surface of intake manifold by guiding


it against dowel pins.

– Fit intake manifold onto dowel pins on cylinder head.


– Tighten bolts according to specified torque and tightening
sequence ⇒ Fig. ““Differences when tightening intake mani‐
fold”“, page 449 .

Caution

If a new intake manifold has been installed, the cooling sys‐


tem must be flushed and the coolant must be renewed to
ensure optimum surface protection ⇒ page 237 .

If the existing intake manifold has been installed:


– Add coolant ⇒ page 215 .
Specified torques
♦ ⇒ Fig. ““Differences when tightening intake manifold”“, page
449
♦ ⇒ Fig. ““Installing air ducts with screw-type clips”“, page 443
♦ ⇒ o5.1 verview – intake manifold”, page 447
♦ ⇒ o1.1 verview - sump/oil pump”, page 184
♦ ⇒ o3.2 verview - fuel rail”, page 419
♦ ⇒ o3.1 verview - coolant pipes”, page 294

5. Intake manifold 455


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♦ ⇒ o4.1 verview - air filter housing”, page 441


♦ ⇒ o4.3 verview – radiator cowl and radiator fan”, page 326
♦ ⇒ o5.1.2 verview – exhaust gas recirculation, exhaust gas
recirculation valve 1GX5”, page 600
♦ ⇒ o8.1 verview - high-pressure pump”, page 488

5.3 Removing and installing throttle valve


module -J338-
Special tools and workshop equipment required
♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

♦ Protective mat -VAS 531003-


Removing
– Remove engine cover panel ⇒ page 61 .
– Remove air duct ⇒ page 443 .
– Remove air filter housing ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

456 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Drain coolant ⇒ page 213 .


– Remove coolant pipe (top front) ⇒ page 298 .
– Remove front coolant pipe ⇒ page 299 .
– Remove air hose -1-.

– To do this, loosen clamps -arrows-.


– Release and pull off connectors -3- and -5-.

– Open clamps -arrows-.


– Pull coolant hoses -2- off throttle valve module -J338-.
– Pull hose -4- off connecting piece -1-.
– Unscrew bolts -2- from connecting piece -1-.

5. Intake manifold 457


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– Unscrew bolt -3-.

– Remove throttle valve module -J338- with connecting piece.


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

Note

Renew seals and O-ring after removal.

– When fitting throttle valve module -J338-, pay attention to


dowel pins.
– Install coolant pipes (top front) ⇒ page 294 .
– Install air filter housing ⇒ page 443 .
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o5.1 verview – intake manifold”, page 447

458 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

6 Senders and sensors


⇒ a6.1 nd installing fuel pressure regulating valveN276”, page
459
⇒ f6.2 uel pressure regulating valveN276”, page 461
⇒ a6.3 nd installing fuel pressure senderG247”, page 463
⇒ a6.4 nd installing air mass meterG70”, page 464
⇒ a6.5 nd installing pressure differential senderG505”, page
466
⇒ a6.6 nd installing exhaust gas pressure sensor 1G450”, page
467
⇒ a6.7 nd installing charge air temperature sender ahead of
charge air coolerG810”, page 469
⇒ a6.8 nd installing charge air temperature sender after charge
air coolerG811”, page 469
⇒ a6.9 nd installing fuel temperature senderG81”, page 470
⇒ a6.10 nd installing control unit for NOx senderGX30”, page
471
⇒ o6.11 verview - NOx sender control unitGX30”, page 475
⇒ a6.12 nd installing control unit 2 for NOx senderGX46”, page
476
⇒ a6.13 nd installing particle sensorG784”, page 478

6.1 Removing and installing fuel pressure


regulating valve -N276-
Special tools and workshop equipment required
♦ Insert tool, 30 mm -T10553-

♦ Torque wrench -V.A.G 1332-

6. Senders and sensors 459


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Removing
– Remove engine cover panel ⇒ page 61 .
– Release and unplug electrical connector -2-.

– Remove fuel rail ⇒ page 437 .


– Do not loosen fuel pressure regulating valve -N276- -1- on
fuel rail in installed condition.

Note

Clamp fuel rail in a vice to remove pressure regulating valve.


Use protective jaw covers for the vice. Position the fuel rail
in such a way that no force is exerted on the threaded connec‐
tions for the high-pressure lines or the retaining tabs for secur‐
ing the fuel rail to the cylinder head.

– Clamp fuel rail in vice with jaw protectors.


– Loosen fuel pressure regulating valve -N276- -1- fuel rail.
– Before removal, clean area around thread for fuel pressure
regulating valve -N276- using e.g. commercial cleaning solu‐
tion.
• Under no circumstances may dirt enter the hole of the fuel
rail.
• Do not allow any cleaning agent to get into the connector,
clean it carefully.
– Unbolt fuel pressure regulating valve -N276- -2- from fuel rail
-1-.

– Dry fuel pressure regulating valve -N276-.

460 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Extract dirt from hole of high pressure accumulator (threads


and sealing surface). Do not use tools or other instruments
for this purpose.
– Seal off open connection in high-pressure reservoir with
clean plug.
Installing

Note

Coat start of thread and deformable sealing lip of fuel pressure


regulating valve -N276- with diesel fuel.

– Tighten fuel pressure regulating valve -N276- by hand.


– Install fuel rail ⇒ page 437 .
– Align fuel pressure regulating valve -N276- -1- using suitable
workshop equipment.

– Turn valve in such a way that connector can be connected to


connection -2- free of tension.
– The installation position of connection -2- may differ.
– Fill/bleed fuel system ⇒ page 410 .
– Fit engine cover panel ⇒ page 61 .
– Following renewal, reset learnt values ⇒ Vehicle diagnostic
tester.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Reset adaptation values of engine ctrl.
module
♦ Reset learnt values of dosing unit and pressure
regulating valve
Specified torques
♦ ⇒ o3.2 verview - fuel rail”, page 419

6.2 Checking fuel pressure regulating


valve -N276-
Special tools and workshop equipment required
♦ Measuring container, fuel-resistant
Procedure
– Remove engine cover panel ⇒ page 61 .

6. Senders and sensors 461


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release hose clip -arrow- and detach fuel return hose from
high-pressure reservoir.
– Seal open return line connection with a blanking plug.

Caution

Danger of functional impairment due to contamination/soiling


♦ Observe rules for cleanliness ⇒ page 7 .

– Connect auxiliary hose -3- to return connection of high pres‐


sure accumulator -2-.

1) Check with engine running


– Start engine and run at idling speed.
• Specified amount in 30 seconds: greater than 75 ml
If the specification is not attained, the fuel pressure regulating
valve -N276- is defective.
2) Check with engine running
If condition in 1) is met, increase engine speed ≥ 2000 revs/min.
• Specification: return volume 0 ml
• Droplets are allowed

462 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

• If the specification is not attained, the fuel pressure regulat‐


ing valve -N 276- is defective.
3) If it is no longer possible to start engine
Carry out check at starter speed.
• Specification: return volume 0 ml
• Droplets are allowed
• If the specification is not attained, the fuel pressure regulat‐
ing valve -N 276- is defective.
– Fit engine cover panel ⇒ page 61 .

6.3 Removing and installing fuel pressure


sender -G247-
Special tools and workshop equipment required
♦ Hexagon key extension, 27 mm -T40218-

Removing
– Remove engine cover panel ⇒ page 61 .
– Before removal, clean area around thread for fuel pressure
sender -G247- using, for example, commercially available
cold cleaning solvent.
• Make sure no dirt gets into opening in high-pressure reser‐
voir.
• Do not allow any cleaning agent to get into the connector,
clean it carefully.
– Dry fuel pressure sender -G247-.
– Separate electrical connector -arrow-.

– Unscrew fuel pressure sender -G247- using socket, 27 AF


-T40218-.

6. Senders and sensors 463


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Extract dirt from hole of high pressure accumulator (threads


and sealing surface). Do not use tools or other instruments
for this purpose.
– Seal off opening in high-pressure reservoir with a plug.
Installing

Note

♦ Check that sealing surfaces (deformable sealing lip) and


threads on fuel pressure sender -G247- are undamaged.
Reusing fuel pressure sender -G247- if possible if it has
been tested OK.
♦ Also check sealing surface in hole of fuel rail.
♦ The beginning of the thread and the deformable sealing lip
of the fuel pressure sender -G247- must be coated with
diesel fuel.

– Tighten fuel pressure sender -G247- by hand.


– Then tighten fuel pressure sender -G247- to specified tor‐
que.
– Fill/bleed fuel system ⇒ page 410 .
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o3.2 verview - fuel rail”, page 419

6.4 Removing and installing air mass me‐


ter -G70-
Removing
– Remove engine cover panel ⇒ page 61 .
– Release and pull off connector on air mass meter -G70- -6-.

– Press release tabs on crankcase breather hose -4-, and


remove hose from intake hose -1-.

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, release and pull off connector on intake hose -1-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Unscrew bolts -arrows-.

– Pull air mass meter -G70- off air filter.


Installing
To ensure the proper function of the air mass meter -G70- it is
important to adhere to the following work sequences.

Note

♦ If the air filter element is very dirty or wet, particles of dirt


or water may reach the air mass meter and falsify the meas‐
ured air mass value. This would lead to loss of power as a
smaller injection quantity is calculated.
♦ Always use Genuine part for air filter element.
♦ Always renew seal if damaged (infiltrating air).
♦ Use a silicone-free lubricant to install the air hose and seal.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Check for salt residue, dirt and leaves in air mass meter and
air hose (clean air side).
– Check intake duct for contamination up to air filter element.
Clean air filter housing, if contamination is found.

6. Senders and sensors 465


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– Clean top and bottom part of air filter housing by rinsing out
or using a vacuum cleaner if necessary.
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o2.1 verview - charge air system”, page 377
If air mass meter -G70- was renewed, reset learnt values in
engine control unit using vehicle diagnostic tester:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics
♦ 0001 - Engine electronics functions
♦ 0001 - Reset adaptation values of engine ctrl.
module
♦ Select: Reset after exchanging air mass meter

6.5 Removing and installing pressure dif‐


ferential sender -G505-

Note

Overview of fitting locations ⇒ page 584 .

– Remove engine cover panel ⇒ page 61 .


– Open heat insulation sleeve -1-.

– Release and unplug electrical connector -2-.


– Unscrew bolt -4- and remove pressure differential sender
-G505- -3- from bracket.
– Release hose clip, and pull off hose.
– Before disconnecting hose from pressure differential sender
-G505-, spray hose with suitable release agent.

Caution

Irreparable damage to pressure differential sender can be


caused if the connection breaks off.
♦ Carefully disconnect hose from connection, taking care
to keep hose straight.

466 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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

Note

♦ Make sure that hose is securely fitted and that there are no
leaks.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Fit engine cover panel ⇒ page 61 .


Specified torques
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ o2.1 verview – emission control”, page 516

6.6 Removing and installing exhaust gas


pressure sensor 1 -G450-

Note

♦ The exhaust gas pressure sensor 1 -G450- determines the


loading of the particulate filter.
♦ Overview of fitting locations ⇒ page 584 .

Removing
– Remove engine cover panel ⇒ page 61 .
– Open heat insulation sleeve -1-.

– Release and unplug electrical connector -5-.


– Unscrew bolt -7-, and remove exhaust gas pressure sensor
1 -G450- -6- from bracket.
– Before removing, spray solvent on hose of exhaust gas
pressure sensor 1 -G450-.
– Release hose clip -8-, and pull off hose.

6. Senders and sensors 467


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Caution

Irreparable damage to pressure differential sender can be


caused if the connection breaks off.
♦ Carefully disconnect hose from connection, taking care
to keep hose straight.

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

Note

♦ Make sure that hose is securely fitted and that there are no
leaks.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ Depending on the version, the control lines may be different
in length.

If a new control line is installed:

– Note different length of control lines.


– If a new control line -1 - is installed, it may have to be
adjusted in length.
– The control line must be shortened by dimension -a-.
a - 45 mm
– Measure dimension on upper side of control line.
– Shorten control line using suitable workshop equipment.
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ o2.1 verview – emission control”, page 516

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

6.7 Removing and installing charge air


temperature sender ahead of charge
air cooler -G810-
Removing
– Remove engine cover panel ⇒ page 61 .
– Release and pull off respective connector -2-.

1- Charge air temperature sender after charge air cooler -


G811-
2- Charge air temperature sender before charge air cooler
-G810-
– Unscrew relevant charge air temperature sender.
Installing
Install in reverse order of removal, observing the following:
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o5.1 verview – intake manifold”, page 447

6.8 Removing and installing charge air


temperature sender after charge air
cooler -G811-
Removing
– Remove engine cover panel ⇒ page 61 .
– Release and pull off respective connector -1-.

1- Charge air temperature sender after charge air cooler -


G811-

6. Senders and sensors 469


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2- Charge air temperature sender before charge air cooler


-G810-
– Unscrew relevant charge air temperature sender.
Installing
Install in reverse order of removal, observing the following:
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o5.1 verview – intake manifold”, page 447

6.9 Removing and installing fuel tempera‐


ture sender -G81-
Removing
Special tools and workshop equipment required
♦ Torque wrench -VAS 6854-

♦ Tool insert, 17 mm -T10395/3-

– Remove engine cover panel ⇒ page 61 .


– Release and unplug electrical connector -1-.

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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.

– Unscrew fuel temperature sender -G81-.


– Collect escaping fuel with a cloth.
Installing
Install in reverse order of removal, observing the following:
– Renew oil seal -3-.

– Make sure that seal -2- is firmly seated.


– Screw fuel temperature sender -G81- into adapter -4-.
– Checking fuel system for leaks ⇒ page 410 .
– Fit engine cover panel ⇒ page 61 .
Specified torque
Component Specified torque
Fuel temperature sender -G81- 2 Nm

6.10 Removing and installing control unit for


NOx sender -GX30-
⇒ a6.10.1 nd installing control unit for NOx senderGX30, Passat
and Arteon”, page 471
⇒ a6.10.2 nd installing control unit for NOx senderGX30, Ti‐
guan”, page 473

6.10.1 Removing and installing control unit for


NOx sender -GX30-, Passat and Ar‐
teon
Special tools and workshop equipment required

6. Senders and sensors 471


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Socket 22 mm -T10491-

♦ Lambda probe open ring spanner set -3337/7-

Removing
The control unit for NOx sender -GX30- comprises the NOx
sender -G295- and the control unit for NOx sender -J583-.
Fitting location ⇒ Item 11 (page 397)
– Remove engine cover panel ⇒ page 61 .
– Unbolt control unit for NOx sender -GX30- -2- together with
bracket -1- from air filter carrier.

– To do this, unscrew bolt -arrow-.


– Remove control unit for NOx sender -GX30- together with
bracket.
– Release and unplug electrical connector -2-.

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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release control unit at bottom of guide -arrow A- and pull off


towards front.
– Pull control unit -1- out of guide -arrow B-.
– Unscrew control unit for NOx sender -GX30- -4- from turbo‐
charger.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Make sure the guide lug of the bracket is properly seated in
the recess of the air filter carrier.
Specified torques
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ a3.1 nd installing engine cover”, page 61
♦ ⇒ o4.1 verview - air filter housing”, page 441

6.10.2 Removing and installing control unit for


NOx sender -GX30-, Tiguan
Special tools and workshop equipment required

6. Senders and sensors 473


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Socket 22 mm -T10491-

♦ Lambda probe open ring spanner set -3337/7-

Removing
The control unit for NOx sender -GX30- comprises the NOx
sender -G295- and the control unit for NOx sender -J583-.
Installation location of control unit for NOx sender -J583- ⇒ Item
11 (page 397) :
Installation location of NOx sender -G295- ⇒ Item 2 (page 494) :
– Remove engine cover panel ⇒ page 61 .
– Unbolt control unit for NOx sender -GX30- -1- from air filter
carrier.

– To do this, unscrew bolt -3- from air filter carrier.


– Release and unplug electrical connector -2-.
– Unclip control unit for NOx sender -GX30- from bracket.
– Unclip wiring harness on brake master cylinder.
– Guide out wiring harness from brackets on bulkhead.

474 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew control unit for NOx sender -GX30- -4- from turbo‐
charger.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Make sure that guide lug of bracket -4- is properly seated in
recess of air filter carrier.

Specified torques
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ a3.1 nd installing engine cover”, page 61
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o6.11 verview - NOx sender control unitGX30”, page 475

6.11 Assembly overview - NOx sender control unit -GX30-

6. Senders and sensors 475


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - NOx sender control unit


-GX30-
❑ Consisting of
❑ NOx sender -G295-
❑ Control unit for NOx
sender -J583-
2 - Bolt
❑ 8 Nm
3 - Bracket
❑ For control unit for NOx
sender -GX30-
4 - Carrier for air filter housing
❑ Removing and instal‐
ling ⇒ page 444

6.12 Removing and installing control unit 2


for NOx sender -GX46-
Special tools and workshop equipment required
♦ Socket 22 mm -T10491-

476 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Lambda probe open ring spanner set -3337/7-

The control unit 2 for NOx sender -GX46- consists of control


unit for NOx sender 2 -J881- and NOx sender 2 -G687-:
Removing
– Detach underbody cladding at front left on inside, and lower
it ⇒ General body repair, exterior; Rep. gr. 66; Underbody
cladding; Removing and installing underbody cladding.
– Release and pull off connector -3-.

– Unscrew NOx sender 2 -G687- -4- from front exhaust pipe


-8-. To do this, use a suitable tool from the list of tools.
– Guide out wiring harness from retainers -5- and free off.
– Remove clips -arrows- from NOx sender 2 -G687- on under‐
body.
– Unscrew clips to do this. The clips will be damaged irrepara‐
bly during removal.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Renew clips -arrows-.
Specified torques
♦ ⇒ o1.7.3 verview - front exhaust pipe, vehicles with control
unit 2 for NOx senderGX46 and particulate sensorG784”,
page 513

6. Senders and sensors 477


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody


cladding; Overview of fitting locations - trims

6.13 Removing and installing particle sensor


-G784-
Special tools and workshop equipment required
♦ Socket 22 mm -T10491-

♦ Lambda probe open ring spanner set -3337/7-

Removing
– Detach underbody cladding at front left on inside, and lower
it ⇒ General body repair, exterior; Rep. gr. 66; Underbody
cladding; Removing and installing underbody cladding.
– Release and pull off connector -6-.

478 Rep. gr.23 - Mixture preparation - injection


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– Unscrew particulate sensor -G784- -2- from front exhaust


pipe -8-. To do this, use a suitable tool from the list of tools.
– Guide out wiring harness from retainers -5- and free off.
– Remove particulate sensor -G784- from bracket -1- on un‐
derbody.
– To do this, actuate locking mechanism of retaining pins from
bracket -1-.
– To remove bracket -1-, remove clips -arrows- on underbody.
– Unscrew clips to do this. The clips will be damaged irrepara‐
bly during removal.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
– Renew clips -arrows-.
Specified torques
♦ ⇒ o1.7.3 verview - front exhaust pipe, vehicles with control
unit 2 for NOx senderGX46 and particulate sensorG784”,
page 513
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Overview of fitting locations - trims

6. Senders and sensors 479


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

7 Engine control unit


⇒ a7.1 nd installing engine control unitJ623”, page 480

7.1 Removing and installing engine control


unit -J623-
⇒ a7.1.1 nd installing engine control unitJ623”, page 480
⇒ a7.1.2 nd installing engine control unitJ623 (with metal lock‐
ing plate)”, page 481
⇒ a7.1.3 nd installing engine control unitJ623 (with protective
housing)”, page 484

7.1.1 Removing and installing engine control


unit -J623-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove air filter housing ⇒ page 443 .
– If the engine control unit -J623- is renewed, the adaption val‐
ues must be read out and stored before the engine control
unit -J623- is removed.
– The procedure is described in “Guided Functions” mode, test
sequence/function “Replace engine control unit”. Use -vehi‐
cle diagnostic tester- for this.
– Save adaption values in a file.
– After you have saved the adaption value file, switch off igni‐
tion,
– Withdraw ignition key.

Note

If the adaption values of the injectors cannot be read from the


old (defective) engine control unit anymore, the adaption values
must be entered manually into the new engine control unit.

Caution

If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence. Therefore, the
battery must always be disconnected before removing the
engine control unit from its bracket ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.

– Release retaining clip -arrow- and take out engine control


unit -J623-.

480 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connectors.


Installing
Install in reverse order of removal, observing the following:
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Use ⇒ Vehicle diagnostic tester to activate engine control
unit.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Renew engine control unit

7.1.2 Removing and installing engine control


unit -J623- (with metal locking plate)
Special tools and workshop equipment required
♦ Hot air blower -VAS 1978/14A- -item 1- with nozzle -2- from
wiring harness repair set -VAS 1978 B-

♦ Small grinder (commercially available)


♦ Vehicle diagnostic tester
Removing
– Remove air filter housing ⇒ page 443 .
– If the engine control unit -J623- is renewed, the adaption val‐
ues must be read out and stored before the engine control
unit -J623- is removed.
– The procedure is described in “Guided Functions” mode, test
sequence/function “Replace engine control unit”. Use -vehi‐
cle diagnostic tester- for this.
– Save adaption values in a file.
– After you have saved the adaption value file, switch off igni‐
tion,

7. Engine control unit 481


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Withdraw ignition key.

Note

If the adaption values of the injectors cannot be read from the


old (defective) engine control unit anymore, the adaption values
must be entered manually into the new engine control unit.

Caution

If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence. Therefore, the
battery must always be disconnected before removing the
engine control unit from its bracket ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.

– Release retaining clip -arrow- and take out engine control


unit -J623-.

– Make groove (for a screwdriver) in head of shear bolt -1-


using a small grinder -2-.

482 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.

– Set the hot air blower as shown in illustration, i.e.: potenti‐


ometer for temperature regulation -2- set to maximum heat‐
ing power and 2-stage switch for air volume -3- set to posi‐
tion 3.

WARNING

Risk of burns from hot air blower.


♦ When heating up the thread of the locking element, the
shear-head bolts and parts of the sheet-metal housing
become hot as well. Ensure to only heat up the thread
and no surrounding components. Cover surrounding
components, if necessary.

– Hold hot air blower -VAS 1978/14A- with nozzle attachment


-arrow- to thread of shear bolt and heat thread for about 20
to 30 seconds.

– Unscrew shear bolt -1- with screwdriver -2-.

7. Engine control unit 483


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Detach metal locking plate from connectors for engine con‐


trol unit -J623-.
– Release and pull off connectors.
Installing
Install in reverse order of removal, observing the following:
– The metal locking plate must always be re-fitted on the en‐
gine control unit -J623-.
– Clean threaded holes for shear bolts. A thread chaser is
suitable for cleaning.
– Always use new shear bolts.
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Use ⇒ Vehicle diagnostic tester to activate engine control
unit.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Renew engine control unit

7.1.3 Removing and installing engine control


unit -J623- (with protective housing)
Removing
– Remove air filter housing ⇒ page 443 .
To remove protective housing -1-, unscrew shear bolts -arrows-
as follows:

– Make groove (for a screwdriver) in head of shear bolt -1-


using a small grinder -2-.

484 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.

– Set the hot air blower as shown in illustration, i.e.: potenti‐


ometer for temperature regulation -2- set to maximum heat‐
ing power and 2-stage switch for air volume -3- set to posi‐
tion 3.

WARNING

Risk of burns from hot air blower.


♦ When heating up the thread of the locking element, the
shear-head bolts and parts of the sheet-metal housing
become hot as well. Ensure to only heat up the thread
and no surrounding components. Cover surrounding
components if necessary.

– Heat head of shear bolt -1- for approx. 20 to 30 seconds.

7. Engine control unit 485


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew shear bolt -1- with screwdriver -2-.

Caution

If the engine (motor) control unit comes into contact with the
positive battery terminal, permanent damage to the engine
(motor) control unit will be the consequence. Therefore, the
battery must always be disconnected before removing the
engine control unit from its bracket ⇒ Electrical system; Rep.
gr. 27; Battery; Disconnecting and connecting battery.

– Release fastener -arrow- and detach engine control unit -1-.

– Release and pull off connectors for engine (motor) control


unit -J623-.
Installing
Install in reverse order of removal, observing the following:
– It is essential that the engine (motor) control unit -J623- be
provided with the protective housing again.

486 Rep. gr.23 - Mixture preparation - injection


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– Clean the threaded holes for the shear-head bolts of locking


compound residues. A thread chaser is suitable for cleaning.
– Always use new shear bolts.
After having installed the new engine control unit, the following
work must be carried out:
– Use ⇒ Vehicle diagnostic tester to activate engine control
unit.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Renew engine control unit

7. Engine control unit 487


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8 High-pressure pump
⇒ o8.1 verview - high-pressure pump”, page 488
⇒ a8.2 nd installing high-pressure pump”, page 490

8.1 Assembly overview - high-pressure pump

488 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - High-pressure line
❑ Between fuel rail and
high-pressure pump
❑ Removing ⇒ page 431
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 432
2 - Fuel return hose
❑ To fuel tank
3 - Clip
4 - Clip
5 - Fuel supply hose
❑ From fuel filter.
6 - Fuel metering valve -
N290-
7 - High-pressure pump
❑ With fuel metering
valve -N290-.
❑ Removing and instal‐
ling ⇒ page 490

Cau‐
tion
Running when dry cau‐
ses irreparable damage
to high-pressure pump.
If♦the high-pressure
pump is removed or re‐
newed, it is important to
fill and bleed the fuel
system before the en‐
gine is started for the
first time ⇒ page 410 .

❑ After renewing, readapt learnt values using vehicle diagnostic tester.


8 - High-pressure line
❑ Between fuel rail and high-pressure pump
❑ Removing ⇒ page 431
❑ Observe all instructions for installing high-pressure pipes ⇒ page 432
9 - Ancillary bracket
❑ Removing and installing ⇒ page 70
10 - Bolt
❑ Qty. 3
❑ Different lengths.
❑ Renew after removal
❑ Specified torque:
♦ Short bolt, 20 Nm + +90°
♦ Long bolt, 20 Nm + 180°
11 - Nut
❑ Use counter-hold tool -T10051- to loosen and tighten
❑ 95 Nm
12 - High-pressure pump toothed belt pulley

8. High-pressure pump 489


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13 - Hub
❑ To remove, use puller -T10489-

8.2 Removing and installing high-pressure


pump
Special tools and workshop equipment required
♦ Counterhold -T10051-

♦ Puller -T10489-

♦ Locking pin -T10492-

490 Rep. gr.23 - Mixture preparation - injection


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Removing

Caution

Danger of functional impairment due to contamination/soiling


Running when dry causes irreparable damage to high-pres‐
sure pump.
♦ If the high-pressure pump has been removed or re‐
newed, it is important to fill and bleed the fuel system
before the engine is started for the first time ⇒ page
410 .

– Remove toothed belt from camshaft ⇒ page 161 .


– Remove high-pressure pipe between fuel rail and high-pres‐
sure pump ⇒ page 431 .
– Mount counter-hold tool -T10051- -A- on high-pressure
pump pulley.

– Hand-tighten nut -arrow-.


– Pull off locking pin -T10492- -B-, and slowly turn high-pres‐
sure pump shaft to a position in which it is not under tension.
– Unscrew nut -arrow- and remove counter-hold tool -T10051-
-A-.
– Remove high-pressure pump pulley.
– Turn back spindle on puller -T10489-.

– Fit puller -T10489-, and guide it into guides.


– Engage puller -T10489- at hub of high-pressure pump by
turning it clockwise.
– Detach hub of high-pressure pump.

8. High-pressure pump 491


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– Counter-hold bell of puller -T10489- when doing this.


– Remove fuel hoses -2-.

– Disconnect electrical connector -1-.


– Unscrew bolts -arrows-.
– Pull high-pressure pump as far back as possible.
– Lift high-pressure pump at rear.
– Swing out high-pressure pump at rear.
– Carefully remove high-pressure pump.
Installing

Install in reverse order of removal, observing the following:


– Fit hub -arrow- to high-pressure pump shaft.
• The parallel key on the high-pressure pump shaft must en‐
gage in the groove in the hub.
– Place high-pressure pump pulley on hub.
• Contact surface between counterhold and toothed belt
sprocket must be free of oil.
– Screw nut -arrow- onto thread of high-pressure pump shaft.

492 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Apply counter-hold tool -T10051- -A- to toothed belt pulley


and hand-tighten nut -arrow-.
– Turn high-pressure pump sprocket with counter-hold -
T10051- until it can be locked in position with locking pin
-T10492- -B-.
– To do this, insert locking pin -T10492- -B- into fork -2- of hub
and into hole -1- behind it in ancillary bracket.
– Loosen nut -arrow- again.
• It should just be possible to turn high-pressure pump toothed
belt pulley without axial movement.
– Install toothed belt ⇒ page 152 .
– Install high-pressure lines ⇒ page 432 .

Caution

Risk of irreparable damage to high-pressure pump if allowed


to run dry.
♦ If the high-pressure pump has been removed or re‐
newed, it is important to fill and bleed the fuel system
before the engine is started for the first time ⇒ page
410 .

– After renewing high-pressure pump, readapt learnt values


-vehicle diagnostic tester-.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Reset adaptation values of engine ctrl.
module
Specified torques
♦ ⇒ o8.1 verview - high-pressure pump”, page 488

8. High-pressure pump 493


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9 Lambda probe
⇒ o9.1 verview - Lambda probe”, page 494
⇒ a9.2 nd installing Lambda probe”, page 494

9.1 Assembly overview - Lambda probe

1 - Lambda probe 1 before


catalytic converter -GX10-
❑ With Lambda probe -
G39-
❑ With Lambda probe
heater -Z19-.
❑ Removing and instal‐
ling ⇒ page 494
❑ 52 Nm
2 - NOx sender control unit
-GX30-
❑ Comprises NOx sender
-G295- and control unit
for NOx sender -J583-
❑ Removing and instal‐
ling ⇒ page 471
❑ 52 Nm
3 - Exhaust gas temperature
sender 2 -G448-
❑ Removing and instal‐
ling ⇒ page 584
❑ 45 Nm
4 - Exhaust gas temperature
sender 1 -G235-
❑ Removing and instal‐
ling ⇒ page 584
❑ 45 Nm
5 - Bracket
6 - Bolt
❑ 8 Nm

9.2 Removing and installing Lambda probe


⇒ a9.2.1 nd installing Lambda probe 1 before catalytic conver‐
terGX10”, page 494

9.2.1 Removing and installing Lambda probe


1 before catalytic converter -GX10-
Special tools and workshop equipment required

494 Rep. gr.23 - Mixture preparation - injection


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♦ Socket 22 mm -T10491-

Removing
– Remove engine cover panel ⇒ page 61 .
– Remove connector -5- for Lambda probe 1 before catalytic
converter -GX10- from retainer, release it, and pull it off.

– Free off electrical wire.


– Unscrew Lambda probe 1 before catalytic converter -GX10-
-3- from turbocharger.

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

9. Lambda probe 495


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Note

♦ New lambda probes are coated with an assembly paste. The


paste must not get into the slots on the Lambda probe body.
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste
⇒ Electronic Parts Catalogue.
♦ During installation, it is essential that wiring of lambda probe
is reattached in same positions. The lambda probe cable
must be prevented from touching the exhaust pipe.

– Fit engine cover panel ⇒ page 61 .


– After renewing lambda probe, reset learnt values ⇒ Vehicle
diagnostic tester.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Reset adaptation values of engine ctrl.
module
♦ 1 - Reset learnt values of lambda probe
Specified torques
♦ ⇒ o9.1 verview - Lambda probe”, page 494

496 Rep. gr.23 - Mixture preparation - injection


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ o1.1 verview – silencers”, page 497
⇒ a1.2 nd installing front exhaust pipe”, page 501
⇒ a1.3 nd installing rear silencer”, page 504
⇒ e1.4 xhaust system free of stress”, page 508
⇒ e1.5 xhaust system for leaks”, page 508
⇒ p1.6 osition of clamp”, page 509
⇒ o1.7 verview - front exhaust pipe”, page 509

1.1 Assembly overview – silencers


⇒ o1.1.1 verview - silencers, Passat and Arteon”, page 497
⇒ o1.1.2 verview - silencers, Tiguan”, page 499

1.1.1 Assembly overview - silencers, Passat and Arteon

1. Exhaust pipes and silencers 497


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front exhaust pipe


❑ Removing and instal‐
ling ⇒ page 501
❑ Aligning exhaust sys‐
tem free of tension ⇒
page 508 .
2 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ For allocation, refer
to ⇒ Electronic Parts
Catalogue
❑ 7 Nm
3 - Seal
❑ Renew after removal
4 - Bracket
❑ Renew if damaged
5 - Bolt
❑ 20 Nm
6 - Exhaust flap control unit
-J883-
❑ Removing and instal‐
ling ⇒ page 527
7 - Bolt
❑ 9 Nm
8 - Nut
❑ 9 Nm
9 - Retaining loop
❑ Renew if damaged
10 - Bolt
❑ 20 Nm
11 - Bracket
12 - Retaining loop
❑ Renew if damaged
13 - Rear silencer
❑ Aligning exhaust system free of tension ⇒ page 508 .
❑ Removing and installing ⇒ page 504
14 - Clamping sleeve
❑ Align exhaust system free of tension before tightening ⇒ page 508 .
❑ Fitting position ⇒ page 509
❑ Tighten threaded connections evenly.
❑ Specified torque ⇒ page 499
15 - Retaining loop
❑ Renew if damaged
16 - Bracket

498 Rep. gr.26 - Exhaust system


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17 - Bolt
❑ 20 Nm
18 - Retaining loop
❑ Renew if damaged
19 - Bracket
20 - Bolt
❑ 20 Nm

Specified torque for clamp

Variante A - 25 Nm
Variante B - 30 Nm
Tighten threaded connections evenly.
Align exhaust system free of tension before tightening ⇒ page
508 .

1.1.2 Assembly overview - silencers, Tiguan

1. Exhaust pipes and silencers 499


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1 - Rear silencer
❑ Aligning exhaust sys‐
tem free of tension ⇒
page 508 .
❑ Removing and instal‐
ling ⇒ page 506
2 - Bracket
❑ Ensure it is properly
seated when installing
3 - Retaining loop
❑ Renew if damaged
4 - Bracket
❑ Ensure it is properly
seated when installing
5 - Bolt
❑ 20 Nm
6 - Bracket
7 - Clamping sleeve
❑ Fitting position ⇒ page
509
❑ Specified torque ⇒
page 500

Specified torque for clamp

Variante A - 25 Nm

500 Rep. gr.26 - Exhaust system


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Variante B - 30 Nm
Tighten threaded connections evenly.
Align exhaust system free of tension before tightening ⇒ page
508 .

1.2 Removing and installing front exhaust


pipe
⇒ a1.2.1 nd installing front exhaust pipe, Passat and Arteon”,
page 501
⇒ a1.2.2 nd installing front exhaust pipe, Tiguan”, page 502

1.2.1 Removing and installing front exhaust


pipe, Passat and Arteon
Special tools and workshop equipment required
♦ Torque wrench -VAS 6854-

♦ Ratchet insert 1/4" -VAS 6234-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and unplug electrical connector -1-.

1. Exhaust pipes and silencers 501


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– Loosen clamp -2- and push to rear.


– Unscrew bolts -1-.

– Slacken bolt -2- and remove clip.


– Remove front exhaust pipe.
Installing
Install in reverse order of removal, observing the following:
– Renew gasket and screw-type clip after removal.
– Observe installation position. Clamp should not be in contact
with components.
– Align exhaust system free of stress ⇒ page 508 .
Specified torques
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

1.2.2 Removing and installing front exhaust


pipe, Tiguan
Special tools and workshop equipment required

502 Rep. gr.26 - Exhaust system


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♦ Torque wrench -VAS 6854-

♦ Ratchet insert 1/4" -VAS 6234-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Loosen clamp -2- and push to rear.

– If fitted, remove heat insulation sleeve from connector.

1. Exhaust pipes and silencers 503


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– Release and unplug electrical connector -1-.


– Unscrew bolts -1-.

– Slacken bolt -2- and remove clip.


– Remove front exhaust pipe.
Installing
Install in reverse order of removal, observing the following:

Note

Renew gasket and screw-type clip after removal.

– Align exhaust system free of stress ⇒ page 508 .


Specified torques
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

1.3 Removing and installing rear silencer


⇒ a1.3.1 nd installing rear silencer, Passat and Arteon”, page
504
⇒ a1.3.2 nd installing rear silencer, Tiguan”, page 506

1.3.1 Removing and installing rear silencer,


Passat and Arteon
Special tools and workshop equipment required

504 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

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


gearbox jack -VAS 6931-

Removing
– Remove rear tunnel cross-piece ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding.

WARNING

Risk of accident caused by weight of rear silencer.


♦ A second mechanic is required for removal of the rear
silencer.

– Place engine and gearbox jack under silencer.


– Support silencer with engine and gearbox jack.
– Release clamping sleeve -2-, and slide it forwards.

– Detach silencer -1- from mountings -arrows-.


– Unscrew bolts -3- for brackets.
– Remove silencer -1-.
Installing
Install in reverse order of removal, observing the following:
– Ensure proper seating of both mountings -arrows-.
– Align supports on brackets -3- parallel to supports on rear
silencer.

1. Exhaust pipes and silencers 505


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– Note installation position of clamp ⇒ page 509 .


– Align exhaust system free of stress ⇒ page 508 .
Specified torques
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ p1.6 osition of clamp”, page 509
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding

1.3.2 Removing and installing rear silencer,


Tiguan
Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383 A- or engine and
gearbox jack -VAS 6931-

♦ Tensioning strap -T10038-

WARNING

Risk of accident caused by high weight of silencers.


♦ Seek help from a second a mechanic for the following
work.

– Loosen clamp -arrows-, and push it forwards.

506 Rep. gr.26 - Exhaust system


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– Secure exhaust pipe -1- on propshaft with tensioning strap


-2-.

– Place engine and gearbox jack under silencer.


– Support silencer with engine and gearbox jack.
– Unscrew bolts -4-.

– Remove silencer -1-.


Installing
Install in reverse order of removal, observing the following:
– Ensure that both brackets -5- and -6- are seated correctly.
– Align supports on brackets -3- parallel to supports on rear
silencer.

1. Exhaust pipes and silencers 507


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– Align supports for rubber mountings -2- parallel to each oth‐


er.
– Align exhaust system free of stress ⇒ page 508 .
– Note installation position of clamp ⇒ page 509 .
Specified torques
♦ ⇒ o1.1.2 verview - silencers, Tiguan”, page 499
♦ ⇒ p1.6 osition of clamp”, page 509
♦ ⇒ Fig. ““Specified torque for clamp”“, page 500

1.4 Aligning exhaust system free of stress


Procedure
• The exhaust system must be aligned when cold.
– Loosen threaded connections -arrows- on clamp -1-.

– Push exhaust system towards front of vehicle until preload


on rubber mounting for rear silencer -a- = 5 mm.

– Install clamp ⇒ page 509 .


– Evenly tighten bolted connections of clamp.
Specified torques
♦ ⇒ o1.1 verview – silencers”, page 497

1.5 Checking exhaust system for leaks


– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.

508 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Repair any leaks found.

1.6 Installation position of clamp

– Fit clamp in position shown.


• Observe installation position. Clamp should not be in contact
with components
• Bolt -arrow- must not protrude beyond lower edge of clamp.
• Nut points downwards.
Installation dimension for vehicles with marking on exhaust pipe

1 - Clamping sleeve
2 - Exhaust pipe
a - Installation dimension
A - Marking on exhaust system
Installation dimension -a- for clamp:
a - 8.5 mm
Specified torque:
♦ ⇒ Fig. ““Specified torque for clamp”“, page 500

1.7 Assembly overview - front exhaust pipe


⇒ o1.7.1 verview - front exhaust pipe, Passat and Arteon”, page
509
⇒ o1.7.2 verview - front exhaust pipe, Tiguan”, page 510
⇒ o1.7.3 verview - front exhaust pipe, vehicles with control
unit 2 for NOx senderGX46 and particulate sensorG784”, page
513

1.7.1 Assembly overview - front exhaust pipe, Passat and Arteon

1. Exhaust pipes and silencers 509


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front exhaust pipe


❑ Removing and instal‐
ling ⇒ page 501
❑ With ammonia trap -A-
and front silencer -B-
2 - Seal
❑ Renew after removal
3 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ For allocation, refer
to ⇒ Electronic Parts
Catalogue
❑ 7 Nm
4 - Exhaust flap control unit
-J883-
❑ Removing and instal‐
ling ⇒ page 527
5 - Nut
❑ 10 Nm
6 - Bolt
❑ Note different lengths.
❑ 10 Nm
7 - Exhaust flap
❑ Cannot be removed in‐
dividually
8 - Clamping sleeve
❑ Fitting position ⇒ page
509
❑ Specified torque ⇒ page 499
9 - Bolt
❑ 20 Nm
10 - Bracket
❑ Renew if damaged
❑ With mounting for front exhaust pipe
❑ Assembly overview - mounting for front exhaust pipe ⇒ page 511
11 - Subframe
❑ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly overview - subframe

1.7.2 Assembly overview - front exhaust pipe, Tiguan

510 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front exhaust pipe


❑ Removing and instal‐
ling ⇒ page 502
❑ With ammonia trap -A-
and front silencer -B-
2 - Seal
❑ Renew after removal
3 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ For allocation, refer
to ⇒ Electronic Parts
Catalogue
❑ 7 Nm
4 - Exhaust flap control unit
-J883-
❑ Removing and instal‐
ling ⇒ page 527
5 - Nut
❑ 10 Nm
6 - Bolt
❑ Note different lengths.
❑ 10 Nm
7 - Exhaust flap
❑ Cannot be removed in‐
dividually
8 - Clamping sleeve
❑ Fitting position ⇒ page
509
❑ Specified torque ⇒ page 500
9 - Bolt
❑ 20 Nm
10 - Bracket
❑ Renew if damaged
❑ With mounting for front exhaust pipe
❑ Assembly overview - mounting for front exhaust pipe ⇒ page 511
11 - Subframe
❑ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly overview - subframe

A - SCR catalytic converter


B - Front silencer
Assembly overview - mounting for front exhaust pipe:

1. Exhaust pipes and silencers 511


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front exhaust pipe


❑ Assembly overview ⇒
page 509
❑ Removing and instal‐
ling ⇒ page 502
2 - Bolt
❑ 20 Nm
3 - Bracket
❑ Removing and instal‐
ling ⇒ page 512
4 - Securing clip
❑ Not installed in all vehi‐
cles
5 - Pop rivet
❑ If holder is to be re‐
newed, drill out pop riv‐
et and remove retaining
washer
❑ After renewing bracket,
rivet in retaining washer
again

Removing and installing front exhaust pipe bracket

Note

Depending on the equipment level of the vehicle, a retaining


washer for the bracket of the catalytic converter may be instal‐
led. When the vehicle »hits the ground«, the retaining washer
prevents the catalytic converter from slipping out of the bracket.
The retaining washer can also be retrofitted if necessary. For
retrofit parts, refer to ⇒ Electronic parts catalogue (ETKA).

– Remove front exhaust pipe ⇒ page 502 .


To detach bracket from catalytic converter:
– Drill out pop rivets and remove retaining washer ⇒ page
511 .
– Detach bracket from catalytic converter.
To fit bracket with retaining washers:

512 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Check if pop rivets can be inserted into mounting on catalytic


converter. If necessary, widen holes to 7 mm with a drill.
– Fit bracket -1- to mountings on catalytic converter.
– Secure retaining washers -3- with rivets as shown in illustra‐
tion, parallel to rubber part -2-.
Further assembly is basically a reverse of the dismantling se‐
quence.
Specified torque:
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509

1.7.3 Assembly overview - front exhaust pipe, vehicles with control unit 2 for
NOx sender -GX46- and particulate sensor -G784-

1. Exhaust pipes and silencers 513


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ For allocation, refer
to ⇒ Electronic Parts
Catalogue
❑ 7 Nm
2 - Seal
❑ Renew after removal
3 - Front exhaust pipe
❑ Removing and instal‐
ling ⇒ page 501
❑ With ammonia trap -A-
and front silencer -B-
4 - Nut
❑ 10 Nm
5 - Nut
❑ 10 Nm
6 - Exhaust flap control unit
-J883-
❑ Removing and instal‐
ling ⇒ page 527
7 - Connector
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 10 Nm
10 - Clamping sleeve
❑ Fitting position ⇒ page 509
❑ Specified torque ⇒ page 499
11 - Particle sensor -G784-
❑ Removing and installing ⇒ page 478
12 - Cable bracket
13 - Clip
❑ Renew after removal
14 - Bracket
❑ For particulate sensor -G784- control unit
15 - Control unit 2 for NOx sender -GX46-
❑ Removing and installing ⇒ page 476
16 - Bolt
❑ 20 Nm
17 - Bracket
❑ Renew if damaged
❑ With mounting for front exhaust pipe
❑ Assembly overview - mounting for front exhaust pipe Tiguan ⇒ page 511

514 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

18 - Subframe
❑ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly overview - subframe

1. Exhaust pipes and silencers 515


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2 Emission control
⇒ o2.1 verview – emission control”, page 516
⇒ a2.2 nd installing emission control module”, page 523
⇒ a2.3 nd installing exhaust flap control unitJ883”, page 527

2.1 Assembly overview – emission control

516 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Front exhaust pipe


❑ Removing and instal‐
ling ⇒ page 501
❑ Aligning exhaust sys‐
tem free of tension ⇒
page 508 .
2 - Screw-type clamp
❑ Renew after removal
❑ 7 Nm
3 - Seal
❑ Renew after removal
4 - Seal
❑ Renew after removal
5 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ Specified torque and
tightening sequence: ⇒
page 600
6 - Exhaust gas recirculation
cooler
❑ Assembly overview ⇒
page 598
❑ Removing and instal‐
ling ⇒ page 601
❑ Check for leaks ⇒ page
612
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 20 Nm
9 - Bracket
10 - Turbocharger
❑ Assembly overview ⇒ page 341
❑ Removing and installing ⇒ page 354
11 - Screw-type clamp
❑ Observe installation position. Clamp should not be in contact with components
❑ Renew after removal
❑ 7 Nm
12 - Seal
❑ Renew after removal
13 - Bolt
❑ Qty. 2
❑ 20 Nm
14 - Bolt
❑ Qty. 2

2. Emission control 517


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❑ 20 Nm
15 - Bracket
16 - Bracket
17 - Bolt
❑ Screw in by hand as far as stop
❑ 40 Nm
18 - Bolt
❑ 9 Nm
19 - Bolt
❑ Qty. 3
❑ 20 Nm
20 - Bracket
21 - Bracket
22 - Nut
❑ Qty. 2
❑ 20 Nm
23 - Bolt
❑ 9 Nm
24 - Sensor wires
25 - Bolt
❑ Qty. 2
❑ 20 Nm
26 - Centre hex stud
❑ Qty. 2
❑ 20 Nm
27 - Nut
❑ 10 Nm
28 - Coolant pipe
29 - Bolt
❑ Qty. 3
❑ 20 Nm
30 - Bracket
31 - Emission control module
❑ Removing and installing ⇒ page 523

518 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installation and tightening sequence:

– Renew all securing bolts of the emission control module af‐


ter removal.
S Component/bolts Specified torque
t
a
g
e
1 Bolts -arrows A- for bracket -1- 20 Nm
2 Bolts -arrows B- for bracket -2- 40 Nm
3 Bolts -arrows C- for bracket -3- 3 Nm and loosen
again 90 . The
bracket must be free
to move.
Continuation:

S Components/bolts
ta
g
e
4 Fit opened clamp -2- onto connecting piece of emission
control module.
5 Fit emission control module -1- to turbocharger -3-.
6 Attach emission control module -1- with clamp -2- to turbo‐
charger -3-.
7 Attach bolt -arrow-, and tighten it to 1 Nm.

2. Emission control 519


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

S Components/bolts
ta
g
e
8 Emission control module must be in approximate installa‐
tion position.
9 Note installation position of clamp. Use the previously
made marking for proper alignment.
Continuation:

S Component/bolts Specified torque


ta
g
e
1 Fit two-way bracket -2- to out‐ Then, tighten bolt by hand.
0 put funnel.
1 Tighten bolts -3- and -4-. 3 Nm and loosen again 90 .
1 The bracket must be free to
move.
Continuation:

520 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

S Component/bolts Specified torque


ta
g
e
1 Bolt emission control module -1- at top 3 Nm and loosen
2 to bracket -2-. again 90°
1 Bolt emission control module -1- at 3 Nm and loosen
3 bottom to bracket -3-. again 90°
Continuation:

Stage Bolts Specified torque


14 Align emission control mod‐ 15 Nm
ule relative to turbocharger.
15 Tighten bolt -arrow-.
Continuation:

2. Emission control 521


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Stage Bolts Specified torque


16 Tighten bolts -3- and -4-. 20 Nm
Continuation:

S Component/bolts Specified torque


ta
g
e
1 Tighten bolts for bracket -3- on engine. 20 Nm
7
1 Tighten bolts between bracket -3- and 20 Nm
8 emission control module.
1 Tighten bolts on bracket -2-. 20 Nm
9
2 Tighten nuts on bracket -2-. 20 Nm
0

522 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

2.2 Removing and installing emission con‐


trol module
Removing
– Remove injector for reducing agent -N474-, and lay it to one
side with lines connected ⇒ page 559 .
– Release and pull off connector on ABS control unit -
J104-/ABS hydraulic unit -N55- ⇒ Brake system; Rep. gr. 45;
Control unit and hydraulic unit; Removing and installing ABS
control unit J104/ABS hydraulic unit N55.
– Lay connector aside.
– Remove exhaust gas temperature sender 3 -G495- ⇒ page
594 .
– Release hose clips -arrows-.

– Pull hose lines -1- off lines -2-.


– Open heat insulation sleeves -4- and -5-.

– Unscrew nut -arrow B-.


– Unscrew bolt -arrow A-.
– Lay vacuum reservoir -1- with lines connected to one side.
– Unscrew bolt -arrows C-.
– Move retainer with pressure differential senders -2- towards
rear.
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.

2. Emission control 523


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Drain coolant ⇒ page 213 .


– Do not re-connect coolant hoses.
– Remove auxiliary pump for heating -V488- together with
bracket from engine ⇒ page 276 .
– Remove exhaust gas recirculation cooler ⇒ page 601 .
– Remove selector mechanism on gearbox ⇒ Rep. gr. 34; Se‐
lector mechanism; Removing and installing selector mecha‐
nism.
– If present, remove coolant pipes for auxiliary heater/supple‐
mentary heating system ⇒ Auxiliary heater, supplementary
heating system; Rep. gr. 82; Coolant circuit with auxiliary
heater/supplementary heating system.
– Remove high-pressure turbocharger ⇒ page 354 .
– Using engine support -T10533-, push engine as far forwards
as possible.
– Ensure that there is sufficient clearance to all components.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
– Remove bevel box ⇒ Rep. gr. 34; Bevel box.
– Unscrew bolts -3- and -4-.

– Remove bracket -2-.

524 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Open clip -8- and position it on intake funnel of emission


control module.

– Unscrew nuts -2- and -5-.


– Unscrew remaining bolts -4- to -7-.
– Remove emission control module -1-.
– Move emission control module downwards and guide out
between subframe and engine.
– Tilt and turn accordingly when doing so.
Installing
Assemble in reverse order of dismantling. During this proce‐
dure, observe the following:

Note

Attach all cable ties and heat-shielding sleeves in the same


places when installing.

– Renew gaskets, self-locking nuts and screw-type clamp for


emission control module after removal.
– Renew all securing bolts of the emission control module af‐
ter removal.
– Renew gasket -1- between turbocharger and emission con‐
trol module. Use a suitable screwdriver -2- to lever out seal
at recess -arrow-.

2. Emission control 525


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– Guide in emission control module and bring into installation


position.

– Start centre hex stud -7- and screw in.


– Pull away emission control module towards top right.
– Insert screw-type clip -8- between turbocharger and emis‐
sion control module.
– If the screw-type clip cannot be guided in, the bolt -7- is
screwed in too far.
– Fit screw-type clip on turbocharger.
– Fit emission control module on turbocharger.
– Fit screw-type clip and guide in bolt.
– Fit bracket -3- and screw on nuts -2- and -5- loosely.
– Start bolts -4- and screw in loosely by hand.
– Start bolt -6- and screw in loosely by hand.
– Screw in bolt -7- loosely by hand.
– Installation and tightening sequence ⇒ page 519 .
– After renewing emission control module, perform adaption
⇒ Vehicle diagnostic tester.
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions

526 Rep. gr.26 - Exhaust system


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♦ 0001 - Adapt particulate filter learnt values


Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ o1.2.2 verview - cylinder head cover with add-on parts”,
page 119
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ o3.9 verview - injector for reducing agent”, page 566
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carri‐
ers, electronics boxes; Overview of fitting locations - relay
carriers, fuse carriers, electronics boxes
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Lower suspen‐
sion link, swivel joint; Assembly overview – lower suspension
link, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 34; Bevel box; Assembly overview - bevel box
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft
♦ ⇒ Auxiliary heater, supplementary heating system; Rep.
gr. 82; Coolant circuit with auxiliary heater/supplementary
heating system

2.3 Removing and installing exhaust flap


control unit -J883-
Removing
– If fitted, remove heat insulation sleeve from connector.

2. Emission control 527


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– Disconnect electrical connector -1-.


– Unscrew bolts -arrows- and remove exhaust flap control unit
-J883-.
Installing

– Fit new exhaust flap control unit. Make sure that the follower
of the control unit -1- engages properly in the tab of the
exhaust flap -2-.
– Insert new securing bolts, and start new nuts.
– First tighten upper bolt, and then tighten lower bolt.

– Note different bolt lengths.


– Connect connector -1-. If necessary, secure heat insulation
sleeve.
– After renewing exhaust flap control unit -J883-, adapt learnt
values in engine control unit. To do this, switch on ignition,
and select the following menu options on vehicle diagnostic
tester:
♦ Diagnosis-compatible systems

528 Rep. gr.26 - Exhaust system


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♦ 0001 - Engine electronics functions


♦ 0001 - Basic setting
♦ Adapt exhaust flap
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

2. Emission control 529


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3 SCR system (selective catalytic re‐


duction)
⇒ o3.1 verview - tank for reducing agent”, page 530
⇒ o3.2 verview - reducing agent supply line”, page 534
⇒ o3.3 verview - delivery module for reducing agent”, page
535
⇒ a3.4 nd installing reducing agent tank”, page 536
⇒ a3.5 nd installing front section of reducing agent supply line”,
page 542
⇒ a3.6 nd installing delivery module for reducing agent”, page
557
⇒ a3.7 nd installing injector for reduction agentN474”, page
559
⇒ a3.8 nd installing control unit for reducing-agent heaterJ891”,
page 562
⇒ o3.9 verview - injector for reducing agent”, page 566
⇒ r3.10 educing agent tank”, page 567
⇒ a3.11 nd installing rear section of reducing agent supply line”,
page 574
⇒ a3.12 nd installing filler pipe for reducing agent tank”, page
576
⇒ r3.13 educing agent supply line”, page 580
⇒ -3.14 resetting learnt values”, page 583

3.1 Assembly overview - tank for reducing


agent
⇒ o3.1.1 verview - reducing agent tank, Passat and Arteon”,
page 530
⇒ o3.1.2 verview - tank for reducing agent, Tiguan”, page 532

3.1.1 Assembly overview - reducing agent tank, Passat and Arteon

530 Rep. gr.26 - Exhaust system


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1 - Filler neck
2 - Breather hose
3 - Bolt
❑ Qty. 3
❑ 20 Nm
4 - Control unit for reducing
agent heater -J891-
❑ Removing and instal‐
ling ⇒ page 562
5 - Reducing agent tank
❑ with:
♦ Delivery unit
♦ Temperature sender for
reducing agent -G685-
♦ Reducing agent level
sender -G697-
♦ Heater for reducing agent
tank (heater circuit 1) -
Z102-
❑ Fitting location: in area
of luggage compart‐
ment on right side be‐
low underbody
❑ Removing and instal‐
ling ⇒ page 536
6 - Reducing agent line
❑ From delivery module
to injector for reducing
agent -N474-
❑ With heater for reduc‐
ing-agent line (heater
circuit 2) -Z104-
❑ Assembly overview ⇒ page 534
❑ Disconnecting connection ⇒ page 580
7 - Delivery module
❑ with:
♦ Pump for reducing agent -V437-
♦ Reducing agent return flow pump -V561-
❑ Assembly overview ⇒ page 535
❑ Removing and installing delivery module ⇒ page 557 .
8 - Bolt
❑ 5.5 Nm
9 - Delivery unit
❑ Part of reducing agent tank
❑ Cannot be removed
10 - Bolt
❑ 8 Nm
11 - Injector for reducing agent -N474-
❑ Removing and installing ⇒ page 559

3. SCR system (selective catalytic reduction) 531


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❑ Assembly overview ⇒ page 566
12 - Screw-type clamp
❑ 5 Nm

3.1.2 Assembly overview - tank for reducing agent, Tiguan


Assembly overview - reducing agent tank from above ⇒ page
533 :
Assembly overview - reducing agent tank from below:

532 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Reducing agent tank


❑ with:
♦ Delivery unit
♦ Temperature sender for
reducing agent -G685-
♦ Reducing agent level
sender -G697-
♦ Heater for reducing agent
tank (heater circuit 1) -
Z102-
❑ Fitting location: rear
right
❑ Removing and instal‐
ling ⇒ page 536
2 - Delivery unit
❑ Part of reducing agent
tank
❑ Cannot be removed
3 - Bolt
❑ Qty. 3
❑ 20 Nm
4 - Delivery module
❑ with:
♦ Pump for reducing agent -
V437-
♦ Reducing agent return flow
pump -V561-
❑ Assembly overview ⇒
page 535
❑ Removing and instal‐
ling delivery module ⇒
page 557 .
5 - Bolt
❑ 6 Nm
6 - Nut
❑ Qty. 3
❑ 2 Nm
7 - Cover
8 - Reducing agent line
❑ From delivery module to injector for reducing agent -N474-
❑ With heater for reducing-agent line (heater circuit 2) -Z104-
❑ Assembly overview ⇒ page 534

Assembly overview - reducing agent tank from above:

3. SCR system (selective catalytic reduction) 533


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Bracket
❑ On filler tube of fuel
tank
2 - Sealing grommet
❑ Between body and
wheel housing
3 - Cap
4 - Bolt
❑ 8 Nm
5 - Filler tube
❑ Removing and instal‐
ling ⇒ page 576
6 - Reducing agent tank
❑ Removing and instal‐
ling ⇒ page 536
7 - Reducing agent supply
line
❑ Assembly overview ⇒
page 534
❑ Separating supply line
⇒ page 580

3.2 Assembly overview - reducing agent supply line

534 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Reducing agent tank


❑ Assembly overview ⇒
page 530
❑ Removing and instal‐
ling ⇒ page 536
❑ Emptying ⇒ page 567
2 - Reducing agent line
❑ From delivery module
to coupling point at un‐
derbody
❑ With heater for reduc‐
ing-agent line (heater
circuit 2) -Z104-
❑ Assembly overview ⇒
page 534
❑ Disconnecting connec‐
tion ⇒ page 580
❑ Removing and instal‐
ling ⇒ page 574
3 - Electrical connector of de‐
livery line
❑ For heater for reducing-
agent line -Z104-
4 - Electrical connector of de‐
livery line
❑ For heater for reducing-
agent line -Z104-
5 - Support
❑ On right underbody in
area of rear axle
❑ Disconnecting connec‐
tion ⇒ page 580
6 - Clip
❑ 5 Nm
❑ Renew after removal
7 - Reducing agent line
❑ From coupling point at underbody to injector for reducing agent -N474-
❑ With heater for reducing-agent line (heater circuit 2) -Z104-
❑ Assembly overview ⇒ page 534
❑ Disconnecting connection ⇒ page 580
❑ Removing and installing ⇒ page 542
8 - Injector for reducing agent -N474-
❑ Removing and installing ⇒ page 559
❑ Assembly overview ⇒ page 566
9 - Reducing agent line connection
❑ Separating ⇒ page 580
10 - Electrical connector of delivery line
❑ For heater for reducing-agent line -Z104-

3.3 Assembly overview - delivery module for reducing agent

3. SCR system (selective catalytic reduction) 535


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Delivery module for reduc‐


ing agent
❑ Removing and instal‐
ling ⇒ page 557
2 - Spacer sleeve
❑ Qty. 3
❑ Renew after removal
❑ Part of repair kit
3 - Damper
❑ Qty. 3
❑ Renew after removal
❑ Part of repair kit
4 - Seal
❑ Qty. 2
5 - Bolt
❑ Qty. 3
❑ Renew after removal
❑ 6 Nm
6 - Reducing agent line
❑ From delivery module
to injector for reducing
agent -N474-
❑ With heater for reduc‐
ing-agent line (heater
circuit 2) -Z104-
❑ Assembly overview ⇒
page 534
❑ Disconnecting connec‐
tion ⇒ page 580

3.4 Removing and installing reducing


agent tank
⇒ a3.4.1 nd installing reducing agent tank, Passat and Arteon”,
page 536
⇒ a3.4.2 nd installing tank for reducing agent, Tiguan”, page
539

3.4.1 Removing and installing reducing


agent tank, Passat and Arteon
Special tools and workshop equipment required

536 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Engine and gearbox jack -VAS 6931-

♦ Engine bung set -VAS 6122-

Removing
– Emptying tank for reduction agent ⇒ page 567 .
– Remove filler tube ⇒ page 576 .
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding.
– Release and pull off electrical connectors -1- and -3-.

– Release reducing agent line -2- and pull off. Disconnect re‐
ducing agent line ⇒ page 580 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.

3. SCR system (selective catalytic reduction) 537


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Unclip all lines -2- from reducing agent tank -1- -arrows-.

– Place engine and gearbox jack -VAS 6931- equipped with


soft foam padding under tank for reducing agent to support
tank.

– Loosen bolts -arrows- of tank for reducing agent -1-.

– Carefully lower reducing agent tank, taking care not to dam‐


age filler neck.

Note

For reasons of clarity, the engine and gearbox jack is not


shown.

– Lower reducing agent tank using engine and gearbox jack


-VAS 6931-.
– Additionally support tank for reducing agent by hand while
doing so.

538 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installing
Install in reverse order of removal, observing the following:
– Ensure lines are secured properly by pulling.
– Check that all lines are clipped into tank for reducing agent.
– Adapt learnt value for SCR system after reducing agent has
been drained or after components have been renewed ⇒
page 583 .
Specified torques
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding

3.4.2 Removing and installing tank for reduc‐


ing agent, Tiguan
Special tools and workshop equipment required
♦ Engine and gearbox jack -VAS 6931-

♦ Engine bung set -VAS 6122-

Removing

WARNING

Danger due to escaping reducing agent.


♦ Observe safety precautions when working with reducing
agent ⇒ page 2 .

– Remove rear right wheel housing liner ⇒ General body re‐


pairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - rear wheel housing liner.
– Remove filler tubes for reducing agent tank ⇒ page 576 .

3. SCR system (selective catalytic reduction) 539


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Emptying tank for reduction agent ⇒ page 567 .


– Remove cover -1- on reducing agent tank -2-.

– To do this, unscrew nuts -arrows-.


– Unclip all lines on reducing agent tank -1- -arrows-.

– Unclip, release and pull off connector -3-.


– Release and pull off electrical connectors -1- and -3-.

– Release reducing agent line -2- and pull off. Disconnect re‐
ducing agent line ⇒ page 580 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.

540 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Place engine and gearbox jack -VAS 6931- equipped with
soft foam padding under tank for reducing agent to support
tank.

– Unscrew bolts -arrows- of reducing agent tank -1-.

– Carefully lower reducing agent tank, and guide it out while


doing this.

Note

For reasons of clarity, the engine and gearbox jack is not


shown.

– Lower reducing agent tank using engine and gearbox jack


-VAS 6931-.
– Additionally support tank for reducing agent by hand while
doing so.
Installing
Install in reverse order of removal, observing the following:
– Ensure lines are secured properly by pulling.
– Check that all lines are clipped into tank for reducing agent.
– Adapt learnt value for SCR system after reducing agent has
been drained or after components have been renewed ⇒
page 583 .
Specified torques
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding

3. SCR system (selective catalytic reduction) 541


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.5 Removing and installing front section


of reducing agent supply line
⇒ a3.5.1 nd installing front section of reducing agent supply line,
Passat and Arteon”, page 542
⇒ a3.5.2 nd installing front section of reducing agent supply line,
Tiguan”, page 549

3.5.1 Removing and installing front section


of reducing agent supply line, Passat
and Arteon
Special tools and workshop equipment required
♦ Engine bung set -VAS 6122-

Removing
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
Vehicles with auxiliary heater:

– Detach metering pump -V54- from fuel tank ⇒ Auxiliary heat‐


er, supplementary heating system; Rep. gr. 82; Fuel supply.
– To do this, push metering pump -V54- from bottom towards
top out of mounting.
– Lay metering pump -V54- to one side.
– Disconnect fuel line -3- to auxiliary heater ⇒ Rep. gr. 20;
Push-fit couplings; Disconnecting push-fit couplings.
Continued for all vehicles:
– Disconnect fuel supply lines -1- and -2- at underbody.

542 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Separate fuel lines on underbody ⇒ Rep. gr. 20; Push-fit


couplings, disconnecting push-fit couplings.
Reducing agent supply line retainer, version 1:

– Disconnect reducing agent supply line -1- and -2- at coupling


point in area of rear axle.
– Disconnect connector for reducing agent supply line ⇒ page
580 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Unclip, release and pull off connector -4- of reducing agent
supply line on retainer -3- in area of rear axle.
– Tie up connector towards the rear.
Reducing agent supply line retainer, version 2:

– Unclip reducing agent supply line from retainer -3-, and lay it
aside.
– Disconnect reducing agent supply line -1- and -2- at coupling
point in area of rear axle.
– Disconnect connector for reducing agent supply line ⇒ page
580 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Unclip, release and pull off connector -4- of reducing agent
supply line on retainer -3- in area of rear axle.
– Tie up connector towards the rear.

3. SCR system (selective catalytic reduction) 543


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Continued for all vehicles:


– Detach underbody cladding on right side and lower ⇒ Gen‐
eral body repair, exterior; Rep. gr. 66; Underbody cladding;
Assembly overview - underbody cladding.
– Unclip retainer -1- on underbody and at lines -2-.

– Unclip reducing agent supply line -3-.


– Secure a pulling aid (e.g. cable or cord) to fuel lines.
– The pulling aid eases reinstallation; choose an appropriate
length.
– Use adhesive tape to secure pulling aid.
– Lower vehicle using lifting platform.
– Open plug-in connectors -A- and -B- for fuel lines and pull
off fuel lines. Disconnect plug-in connectors ⇒ Rep. gr. 20;
Plug-in connectors; Disconnecting plug-in connectors.

– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.
– Separate supply line for reducing agent at injector for reduc‐
ing agent -N474- ⇒ page 559 .
– Release and pull off connector -2- on coolant expansion
tank.

544 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip, release and pull off connector -4-.


– Free off electrical wire.
– Unclip retainer for fuel lines on coolant expansion tank
-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Open retainers -arrows- for refrigerant line -1-.

– Unclip refrigerant line and push to one side.


– Unclip guard -1- from body -arrows-.

– Unclip shield -1- from longitudinal member -2-.


– Detach clip -3- on body.
– Pull out lines upwards.
– While doing this, just turn the lines carefully, do not jerk
them.
– Unclip lines and remove shield upwards.

3. SCR system (selective catalytic reduction) 545


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull supply line for reducing agent and fuel lines together
forwards into engine compartment and out of guide tunnel.
– Turn reducing agent supply line in such a way that supply
line can be guided into wiring duct.
– If present, detach supply line for reducing agent -1- from
retaining clip -2- for lines.

Installing:
– Detach pulling aid from old lines.
– Make sure that the sealing caps are properly seated on the
new lines.
– If necessary, seal open lines with suitable plugs from engine
bung set -VAS 6122-.

Note

♦ The fuel line, breather line and fuel line for auxiliary heater
are installed together.
♦ If necessary, use adhesive tape to fix the lines in position.

– Insert lines into guides on shield as shown in illustration, and


clip them in ⇒ page 548 .
– Do not clip in fuel lines in upper area of shield until after they
have been guided in ⇒ page 548 .
– Secure pulling aid to fuel lines.
– Use adhesive tape to secure pulling aid.
– Make sure that the pulling aid is only attached in the front
area of the lines.
– Close slotted guide at bottom area of shield with adhesive
tape to prevent lines from slipping out.
– Attach threading aid -1-, as shown.

546 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, clip reducing agent supply line into retaining clip for
the lines.
– Attach connectors -3- to supply line as shown in illustration.

Note

♦ The threading aid is supplied via t⇒ Electronic parts cata‐


logue (ETKA).
♦ The threading aid can be ordered via the ⇒ Electronic parts
catalogue (ETKA).
♦ The reducing agent supply line, fuel line, breather line and
fuel line for the auxiliary heater are installed together.
♦ If necessary, use adhesive tape to fix the lines in position.

– Position fuel lines together with shield at opening in longitu‐


dinal member.
– Slide supply line for reducing agent and fuel lines together
from front to rear.
– Clip supply line for reducing agent into retaining clip for lines.
– Clip lines into retainer on underbody -1-.

– Then clip retainer onto underbody


– Reconnect supply line for reducing agent and electrical con‐
nection and clip into retainer.
– Fit metering pump -V54- to mounting, and pull it downwards.
– Make sure that the metering pump -V54- engages properly
in mounting.

3. SCR system (selective catalytic reduction) 547


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installation position of lines on shield:

1- Guide for reducing agent supply line


2- Retainers for lines in area of coupling point
3- Reducing agent supply line
4- Return line
5- Fuel supply line
6- Fuel line for auxiliary heater
7- Guide for fuel line for auxiliary heater
– Slide supply line for reducing agent and fuel lines together
from front to rear.
– Clip supply line for reducing agent into retaining clip for lines.
– Clip lines into retainer on underbody -1-.

– Then clip retainer onto underbody


– Route reducing agent supply line behind wiring harness for
electromechanical parking brake.
– Reconnect supply line for reducing agent and electrical con‐
nection and clip into retainer.
Vehicles with auxiliary heater:
– Fit metering pump -V54- to mounting, and pull it downwards.
– Make sure that the metering pump -V54- engages properly
in mounting.

548 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installation position of fuel lines at coupling point in engine com‐


partment:

1- Fuel supply line


2- Fuel return line
Installation position of fuel lines on underbody:

2 - Fuel return line


3 - Fuel supply line
4 - Fuel line for auxiliary heater
Specified torques:
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding
♦ ⇒ Auxiliary heater, supplementary heating system; Rep.
gr. 82; Fuel supply

3.5.2 Removing and installing front section


of reducing agent supply line, Tiguan
Special tools and workshop equipment required

3. SCR system (selective catalytic reduction) 549


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Engine bung set -VAS 6122-

Removing
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Remove underbody cladding on right side in front of rear
axle ⇒ General body repairs, exterior; Rep. gr. 66; Under‐
body cladding; Assembly overview - underbody cladding.
Vehicles with auxiliary heater:
– Detach metering pump -V54- from fuel tank ⇒ Auxiliary heat‐
er, supplementary heating system; Rep. gr. 82; Fuel supply.
– To do this, push metering pump -V54- from bottom towards
top out of mounting.
– Lay metering pump -V54- to one side.
– Disconnect fuel line -3- to auxiliary heating. Disconnect plug-
in connectors ⇒ Rep. gr. 20; Plug-in connectors; Disconnect‐
ing plug-in connectors.

Continued for all vehicles:


– Disconnect fuel supply lines -1- and -2- at underbody.
– Separate fuel lines on underbody ⇒ Rep. gr. 20; Push-fit
couplings, disconnecting push-fit couplings.
– Disconnect reducing agent supply line -1- and -2- at coupling
point in area of rear axle.

550 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Disconnect connector for reducing agent supply line ⇒ page


580 .
– Unclip, release and pull off connector -4- of reducing agent
supply line on retainer -3- in area of rear axle.
– Tie up connector towards the rear.
– Detach underbody cladding on right side in front of rear axle
⇒ General body repair, exterior; Rep. gr. 66; Underbody
cladding.
– Unclip retainer -1- on underbody and at lines -2-.

– Unclip reducing agent supply line -3-.


– Secure a pulling aid (e.g. cable or cord) to fuel lines.
– The pulling aid eases reinstallation; choose an appropriate
length.
– Use adhesive tape to secure pulling aid.
– Lower vehicle using lifting platform.
– Unclip reducing agent supply line -2- on coolant expansion
tank and on toothed belt guard -arrows B-.

3. SCR system (selective catalytic reduction) 551


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Separate supply line for reducing agent at injector for reduc‐


ing agent -N474- ⇒ page 559 .
– Pull off fuel supply lines -1- and -2-. Disconnect plug-in con‐
nectors ⇒ Rep. gr. 20; Plug-in connectors; Disconnecting
plug-in connectors.

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.

– Unclip fuel lines -1- and -2- from retainer -arrow- on coolant
expansion tank -3-.
– Unbolt fuel filter, and place it on engine with fuel lines con‐
nected ⇒ Rep. gr. 20; Fuel filter; Removing and installing
fuel filter.
– Release and pull off connector -2- on coolant expansion
tank.

– Unclip, release and pull off connector -4-.


– Free off electrical wire.
– Unclip retainer for fuel lines on coolant expansion tank
-arrow-.
– Using a screwdriver, release catches -6-.
– Place coolant expansion tank -1- on engine.
– Open retainers -arrows- for refrigerant line -1-.

552 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip refrigerant line and push to one side.


– If fitted, remove heat shield -1- on ABS hydraulic unit -N55-.

– To do this, unclip heat shield -1- from bracket -2- -arrow-.


Vehicles with auxiliary heater:

– Remove front section of wheel housing liner or front right


wheel housing liner ⇒ General body repairs, exterior; Rep.
gr. 66; Wheel housing liner; Assembly overview - front wheel
housing liner.
– Release and pull off fuel line -7-.
– Unclip fuel line from retainers, and guide it out.
– Unclip retainers for refrigerant lines from body ⇒ Heating, air
conditioning; Rep. gr. 87; Refrigerant circuit; Removing and
installing refrigerant lines with internal heat exchanger.

3. SCR system (selective catalytic reduction) 553


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Guide out fuel line from underneath refrigerant lines and


engine mounting.
Continued for all vehicles:

– Unclip guard -1- from stud on body -arrow-.


– Release and unclip spreader rivet -arrow A-.
– Unclip shield -1- from longitudinal member -2-.
– If fitted, detach clip -4- for fuel line of auxiliary heater -3-
from body.
– Unclip retainer -2- for shield from longitudinal member.
– Pull out lines upwards.
– While doing this, just turn the lines carefully, do not jerk
them.
– Unclip lines and remove shield upwards.
– Pull supply line for reducing agent and fuel lines together
forwards into engine compartment and out of guide tunnel.
– If present, detach supply line for reducing agent -1- from
retaining clip -2- for lines.

Installing:
– Detach pulling aid from old lines.
– Clip supply line for reducing agent into retaining clips -2- for
lines.
– Tie up reducing agent supply line and connector -3-.
– Make sure that the sealing caps are properly seated on the
new lines.
– If necessary, seal open lines with suitable plugs from engine
bung set -VAS 6122-.
– Attach threading aid -1-, as shown.

554 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, clip reducing agent supply line into retaining clip for
the lines.

Note

♦ The threading aid is supplied via t⇒ Electronic parts cata‐


logue (ETKA).
♦ The threading aid can be ordered via the ⇒ Electronic parts
catalogue (ETKA).
♦ The reducing agent supply line, fuel line, breather line and
fuel line for the auxiliary heater are installed together.
♦ If necessary, use adhesive tape to fix the lines in position.

– Insert lines into guides on shield as shown in illustration, and


clip them in ⇒ page 555 .
– Do not clip in fuel lines in upper area of shield until after they
have been guided in ⇒ page 555 .
– Secure pulling aid to fuel lines.
– Use adhesive tape to secure pulling aid.
– Make sure that the pulling aid is only attached in the front
area of the lines.
– Close slotted guide at bottom area of shield with adhesive
tape to prevent lines from slipping out.
– Position fuel lines together with shield at opening in longitu‐
dinal member.
Installation position of lines on shield:

1- Guide for reducing agent supply line


2- Retainers for lines in area of coupling point

3. SCR system (selective catalytic reduction) 555


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3- Reducing agent supply line


4- Return line
5- Fuel supply line
6- Fuel line for auxiliary heater
7- Guide for fuel line for auxiliary heater
– Slide supply line for reducing agent and fuel lines together
from front to rear.
– Clip supply line for reducing agent into retaining clip for lines.
– Clip lines into retainer on underbody -1-.

– Then clip retainer onto underbody


– Reconnect supply line for reducing agent and electrical con‐
nection and clip into retainer.
Vehicles with auxiliary heater:
– Fit metering pump -V54- to mounting, and pull it downwards.
– Make sure that the metering pump -V54- engages properly
in mounting.
Installation position of fuel lines at coupling point in engine com‐
partment:

1- Fuel supply line


2- Fuel return line

556 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installation position of fuel lines on underbody:

2 - Fuel return line


3 - Fuel supply line
4 - Fuel line for auxiliary heater
Specified torques:
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding
♦ ⇒ Auxiliary heater, supplementary heating system; Rep.
gr. 82; Fuel supply

3.6 Removing and installing delivery mod‐


ule for reducing agent
Special tools and workshop equipment required
♦ Torque wrench -VAS 6854-

Removing
– Emptying tank for reduction agent ⇒ page 567 .
– Remove reducing agent tank ⇒ page 536 .
– Place reducing agent tank on a clean surface.
– The supply module must face upwards.
– Clean area around supply module -5-.

3. SCR system (selective catalytic reduction) 557


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows-.


– Carefully lever out delivery module -5- at recess -4-.
– Pull delivery module out of tank for reducing agent.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Do not clean the delivery module for reducing agent with


compressed air.
♦ Clean all components and connections with water and a
lint-free cloth.
♦ All components must be dry when installing them.
♦ Moisten seals with a suitable lubricant before installing
⇒ Electronic parts catalogue (ETKA).
♦ Check seals for damage.

– Clean all components and connections with water and a


lint-free cloth.
– Renew dampers ⇒ Item 3 (page 536) .
– Renew spacer sleeves ⇒ Item 2 (page 536) .
– Renew seals ⇒ Item 4 (page 536) .
– Fit delivery module for reducing agent, and push it into
mounting without tilting.
– Apply the required force over the entire surface.

558 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

There are letters indicated on the supply unit at the tank for
reducing agent.

♦ The letters -S1- to -S3- indicate the tightening sequence.


♦ Tighten the delivery module as follows:
♦ Renew bolts.

Tight‐ Designation of bolts on Position of bolt Specified torque


ening supply unit
se‐
quenc
e
1 S1 Bolt with largest distance to seal
2 S2 Bolt with medium distance to seal 6 Nm
3 S3 Bolt with smallest distance to seal

– Adapt learnt value for SCR system after reducing agent has
been drained or after components have been renewed ⇒
page 583 .
Specified torques
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530
♦ ⇒ o3.3 verview - delivery module for reducing agent”, page
535

3.7 Removing and installing injector for re‐


duction agent -N474-
Special tools and workshop equipment required

3. SCR system (selective catalytic reduction) 559


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Hose clamps to 25 mm -3094-

♦ Spring-type clip pliers -VAS 6362-

♦ Torque wrench -VAS 6854-

♦ Ratchet insert 1/4" -VAS 6234-

♦ Torx insert E8 from socket set -VAS 6928-


♦ TORX bit set -V.A.G 1766-
Removing
– Remove engine cover panel ⇒ page 61 .

560 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unclip, release and pull off connector -4-.

– Unclip, release and pull off connector -3-.

– Lay wiring harness to one side.


– Clamp off coolant hoses -4- using hose clamps to 25 mm
-3094- and remove. To do this, release hose clips.
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Release and pull off reducing agent line -2- ⇒ page 580 .
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Loosen retaining clip -5-. Note different versions when doing
this and use a suitable tool.
– Remove injector for reducing agent -N474-.
Installing

Install in reverse order of removal, observing the following:

3. SCR system (selective catalytic reduction) 561


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

Secure all hose connections with hose clips corresponding to


the series equipment ⇒ Electronic parts catalogue.

– Renew seals.
• Installation position: lugs in injector for reducing agent -
N474- -item 2- must be inserted into respective recesses in
emission control module -1- -arrows-.
– Fit engine cover panel ⇒ page 61 .
– Adapt learnt value for SCR system after reducing agent has
been drained or after components have been renewed ⇒
page 583 .
Specified torques
♦ ⇒ o3.9 verview - injector for reducing agent”, page 566
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530

3.8 Removing and installing control unit for


reducing-agent heater -J891-
⇒ a3.8.1 nd installing control unit for reducing agent heat‐
erJ891, Passat Variant”, page 562
⇒ a3.8.2 nd installing control unit for reducing agent heat‐
erJ891, Passat saloon”, page 563
⇒ a3.8.3 nd installing control unit for reducing-agent heat‐
erJ891, Tiguan”, page 564
⇒ a3.8.4 nd installing control unit for reducing agent heat‐
erJ891, Arteon”, page 565

3.8.1 Removing and installing control unit for


reducing agent heater -J891-, Passat
Variant
Removing
– Open service flap for right tail light ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trims; Assembly
overview - luggage side panel.
– Unclip retainer -1- from body -2-.

– Guide control unit for reducing agent -J891- out through


opening -arrow-.
– Release and pull off electrical connectors -1-.

562 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release locking devices in -direction of arrow- and remove


retainer.
Installing
Install in reverse order of removal. Observe the following:
Specified torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐
partment trims; Assembly overview - luggage compartment
side panel

3.8.2 Removing and installing control unit for


reducing agent heater -J891-, Passat
saloon
Removing
– Remove luggage compartment side panel on right ⇒ Gener‐
al body repairs, interior; Rep. gr. 70; Luggage compartment
trims; Assembly overview - luggage compartment side pan‐
el.
– Unclip control unit for reducing agent heater -J891- from
body.
– Release and pull off electrical connectors -1-.

3. SCR system (selective catalytic reduction) 563


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release locking devices in -direction of arrow- and remove


retainer.
Installing
Install in reverse order of removal. Observe the following:
Specified torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐
partment trims; Assembly overview - luggage compartment
side panel

3.8.3 Removing and installing control unit for


reducing-agent heater -J891-, Tiguan
Removing
– Remove luggage compartment trim at rear ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trims;
Assembly overview - luggage compartment side trim.
– Unclip bracket -3- from body through opening.

– Press catch -arrow- to do so.

564 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release connector -2- and pull off.


– Remove control unit for reducing agent heater -J891- -1-.
Installing
Install in reverse order of removal. Observe the following:
Specified torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐
partment trims; Assembly overview - luggage compartment
side panel

3.8.4 Removing and installing control unit for


reducing agent heater -J891-, Arteon
Removing
– Remove luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trims; Assembly
overview - luggage compartment floor.
– Remove rear lock carrier trim ⇒ General body repairs, interi‐
or; Rep. gr. 70; Luggage compartment trims; Removing and
installing lock carrier trim.
– Release luggage compartment side trim on right ⇒ General
body repairs, interior; Rep. gr. 70; Luggage compartment
trims; Assembly overview - luggage compartment side trim.
– Unclip control unit for reducing agent heater -J891- -1- from
body.

– Release and pull off electrical connectors -2-.


– If necessary, release and pull off retaining clip.
Installing
Install in reverse order of removal. Observe the following:
– If necessary, renew retaining clip ⇒ Electronic parts cata‐
logue.
Specified torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐
partment trims; Assembly overview - luggage compartment
side panel

3. SCR system (selective catalytic reduction) 565


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐


partment trim; Overview of fitting locations - luggage com‐
partment trim
♦ ⇒ General body repairs, interior; Rep. gr. 70; Luggage com‐
partment trims; Assembly overview - luggage compartment

3.9 Assembly overview - injector for reducing agent

1 - Injector for reducing agent


-N474-
❑ Removing and instal‐
ling ⇒ page 559
2 - Clip
3 - Coolant line
❑ Connection diagram ⇒
page 207
4 - Coolant line
❑ Connection diagram ⇒
page 207
5 - Emission control module
❑ Assembly overview - ⇒
page 516
❑ Removing and instal‐
ling ⇒ page 523
6 - Bolt
❑ Renew after removal
❑ Specified torque ⇒
page 566
❑ Note different versions
7 - Screw-type clamp
❑ Renew after removal
❑ Versions ⇒ page 566
8 - Rubber ring
9 - Seal
❑ Renew after removal

Volkswagen Technical Site: https://vwts.ru


Screw-type clip versions

566 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1- Screw-type clip, one-piece design


2- O-ring
3- Bolt, 12 Nm
4- Clamp, two-piece design with eye
5- Clamp, two-piece design with hook
6- Bolt, 8 Nm
7- Securing tab

3.10 Draining reducing agent tank


⇒ r3.10.1 educing agent tank, Passat and Arteon”, page 567
⇒ t3.10.2 ank for reducing agent, Tiguan”, page 571

3.10.1 Draining reducing agent tank, Passat


and Arteon
Special tools and workshop equipment required
♦ Vacuum box -VAS 6557-

♦ AdBlue extraction hose -VAS 6557A/1-

3. SCR system (selective catalytic reduction) 567


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Draining

Note

♦ To keep the following description as short as possible, the


“NOx reducing agent AUS 32” (AdBlue®) is just called “re‐
ducing agent”.
♦ First, the filler neck must be emptied.
♦ Then, the reducing agent tank is emptied via the connection.

WARNING

♦ The reducing agent can irritate skin, eyes and respirato‐


ry organs.
♦ In the event of skin contact with this fluid, immediately
wash off with plenty of water.
♦ Seek medical attention if necessary.
Danger due to escaping reducing agent.
♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, it is necessary
to wait until automatic return of the reducing agent is
completed ⇒ page 3 .

Caution

Make sure that no reducing agent gets onto the trim panels
or parts of vehicle body.
Remove reducing agent with clear water and a lint-free cloth.
If the reducing agent has already crystallised, use warm wa‐
ter and a sponge.
Reducing agent that has not been removed will crystallise
and damage the surface after some time.
Information concerning storage and disposal ⇒ ServiceNet
→ Environmental protection → Workshop disposal! Request
country specific information from importer concerning storage
and disposal.

– Open tank flap, and clean area around filler cap.

– Open cap -1- of tank for reducing agent.

568 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove rear right wheel housing liner ⇒ General body re‐


pairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - rear wheel housing liner.
– Attach AdBlue extraction hose -VAS 6557A/1- to extraction
hose -E-.

Prepare vacuum box -VAS 6557- as follows:

– Close shut-off taps -A-, -B- and -C-.


– Connect coupling -D- to connection on shut-off tap -A-.

– Pressurise compressed air hose with compressed air.


– Open cut-off tap -A-.
A vacuum is now created in the vacuum box -VAS 6557-.
– Close cut-off tap -A- as soon as the pressure gauge shows a
vacuum pressure of 0.8 bar.
– Disconnect coupling -D- from connection on shut-off tap -A-.

3. SCR system (selective catalytic reduction) 569


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Interrupt the compressed air supply through the compressed


air hose.
– Moisten AdBlue extraction hose -VAS 6557A/1- with water
slightly. This will facilitate insertion of AdBlue extraction hose
-VAS 6557A/1- into filler neck.
– Guide AdBlue extraction hose -VAS 6557A/1- approx.
155 cm into filler neck.
– Open shut-off tap -B-.

Note

♦ The reducing agent is then drawn through the filler pipe


and into the vacuum box -VAS 6557- by the vacuum. The
capacity of the vacuum box -VAS 6557- is 11 litres. This
extracted volume is sufficient for removal of the reducing
agent tank.
♦ If the reducing agent tank holds a greater amount of reduc‐
ing agent and the tank must be emptied, repeat the process.

– To empty vacuum box -VAS 6557-, hold connection on shut-


off tap -C- over suitable container and open shut-off taps -A-
and -C-.

Caution

Extracted reducing agent must never be used again. Infor‐


mation concerning storage and disposal ⇒ ServiceNet → En‐
vironmental protection → Workshop disposal! Request coun‐
try specific information from importer concerning storage and
disposal.

– Extract reducing agent completely as described above.

570 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Clean all components and connections with water and a


lint-free cloth.
– When procedure is complete, thoroughly flush out vacuum
box -VAS 6557- and AdBlue extraction hose -VAS 6557A/1-
with water.

3.10.2 Emptying tank for reducing agent, Ti‐


guan
Special tools and workshop equipment required
♦ Vacuum box -VAS 6557-

♦ AdBlue extraction hose -VAS 6557A/1-


Draining

Note

To keep the following description as short as possible, the “NOx


reducing agent AUS 32” (AdBlue®) is simply called reducing
agent.

WARNING

Danger due to escaping reducing agent.


♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, it is necessary
to wait until automatic return of the reducing agent is
completed ⇒ page 3 .
♦ The reducing agent can irritate skin, eyes and respirato‐
ry organs.
♦ In the event of skin contact with this fluid, immediately
wash off with plenty of water.
♦ Seek medical attention if necessary.

3. SCR system (selective catalytic reduction) 571


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Caution

Make sure that no reducing agent gets onto the trim panels
or parts of vehicle body.
Remove reducing agent with clear water and a lint-free cloth.
If the reducing agent has already crystallised, use warm wa‐
ter and a sponge.
Reducing agent that has not been removed will crystallise
and damage the surface after some time.
Information concerning storage and disposal ⇒ ServiceNet
→ Environmental protection → Workshop disposal! Request
country specific information from importer concerning storage
and disposal.

– Open tank flap, and clean area around filler cap.

– Open cap -1- of tank for reducing agent.


– Attach AdBlue extraction hose -VAS 6557A/1- to extraction
hose -E-.

572 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Prepare vacuum box -VAS 6557- as follows:

– Close shut-off taps -A-, -B- and -C-.


– Connect coupling -D- to connection on shut-off tap -A-.
– Pressurise compressed air hose with compressed air.
– Open cut-off tap -A-.
A vacuum is now created in the vacuum box -VAS 6557-.
– Close cut-off tap -A- as soon as the pressure gauge shows a
vacuum pressure of 0.8 bar.
– Disconnect coupling -D- from connection on shut-off tap -A-.

– Interrupt the compressed air supply through the compressed


air hose.
– Moisten AdBlue extraction hose -VAS 6557A/1- with water
slightly. This will facilitate insertion of AdBlue extraction hose
-VAS 6557A/1- into filler neck.
– Insert AdBlue extraction hose -VAS 6557A/1- as far as pos‐
sible into filler neck until it reaches bottom of reducing agent
tank.
– Open shut-off tap -B-.

3. SCR system (selective catalytic reduction) 573


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ The reducing agent is then drawn through the filler pipe


and into the vacuum box -VAS 6557- by the vacuum. The
capacity of the vacuum box -VAS 6557- is 11 litres. This
extracted volume is sufficient for removal of the reducing
agent tank.
♦ If the reducing agent tank holds a greater amount of reduc‐
ing agent and the tank must be emptied, repeat the process.

– To empty vacuum box -VAS 6557-, hold connection on shut-


off tap -C- over suitable container and open shut-off taps -A-
and -C-.

Caution

Extracted reducing agent must never be used again. Infor‐


mation concerning storage and disposal ⇒ ServiceNet → En‐
vironmental protection → Workshop disposal! Request coun‐
try specific information from importer concerning storage and
disposal.

– Extract reducing agent completely as described above.


– Clean all components and connections with water and a
lint-free cloth.
– When procedure is complete, thoroughly flush out vacuum
box -VAS 6557- and AdBlue extraction hose -VAS 6557A/1-
with water.

3.11 Removing and installing rear section of


reducing agent supply line
Removing
– Observe safety precautions when working on the SCR sys‐
tem ⇒ page 2 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
Vehicles with auxiliary heater:
– Detach metering pump -V54- from fuel tank ⇒ Auxiliary heat‐
er, supplementary heating system; Rep. gr. 82; Fuel supply.

574 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– To do this, push metering pump -V54- from bottom towards


top out of mounting.
– Lay metering pump -V54- to one side.
Passat and Arteon:
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding.
Continued for all vehicles:
– Remove rear right underbody cladding ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Underbody cladding.
– Unclip reducing agent supply line on reducing-agent tank ⇒
page 536 .
– Pull reducing agent supply line off delivery module for reduc‐
ing agent.
– Disconnect connector for reducing agent line ⇒ page 580 .
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Disconnect reducing agent supply line -1- and -2- at coupling
point in area of rear axle.

– Disconnect connector for reducing agent supply line ⇒ page


580 .
– Unclip, release and pull off connector -4- of reducing agent
supply line on retainer -3- in area of rear axle.
– Tie up connector towards the rear.
– Unclip supply line for reducing agent from all retainers on
body.
Specified torques
♦ ⇒ Auxiliary heater, supplementary heating system; Rep.
gr. 82; Fuel supply
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding

3. SCR system (selective catalytic reduction) 575


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

3.12 Removing and installing filler pipe for


reducing agent tank
⇒ a3.12.1 nd installing filler pipe for reducing agent tank, Passat
and Arteon”, page 576
⇒ a3.12.2 nd installing filler tube for reducing agent tank, Ti‐
guan”, page 577

3.12.1 Removing and installing filler pipe for


reducing agent tank, Passat and Ar‐
teon
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44; Wheels, tyres and alignment.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - rear wheel housing liner.
– Open tank flap, and clean area around filler cap.

– Clean area around fuel filler neck.


– Unscrew cap -1- for fuel filler neck.
– In order to prevent the ingress of dirt, seal the opening of the
fuel filler neck with a clean plug.
– Remove tank flap unit -2- ⇒ General body repairs, exterior;
Rep. gr. 55; Tank flap unit; Removing and installing tank flap
unit.
– Unscrew bolts -1- and -2- for fuel filler neck.

– Unscrew bolt -3-.

576 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull filler tube -1- towards outside off fuel tank -2-.
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Unclip breather lines -2- and -3- from body.

– Remove wiring harness. To do this, open retainers.


– Detach breather line -3- and filler tube -4- from reducing
agent tank -1-.
– To do so, press release tabs -arrows-.
Installing
Install in reverse order of removal. While doing so, observe the
following:
Specified torques:
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530
♦ ⇒ Rep. gr. 20; Fuel tank; Assembly overview - fuel tank
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- rear wheel housing liner.
♦ ⇒ Running gear, axles, steering; Rep. gr. 44; Wheels, tyres;
Wheel change.
♦ ⇒ General body repairs, exterior; Rep. gr. 55; Tank flap unit;
Assembly overview – tank flap unit

3.12.2 Removing and installing filler tube for


reducing agent tank, Tiguan
– Remove rear right wheel ⇒ Running gear, axles, steering;
Rep. gr. 44; Wheels, tyres and alignment.

3. SCR system (selective catalytic reduction) 577


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove rear right wheel housing liner ⇒ General body re‐


pairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - rear wheel housing liner.
– Open tank flap, and clean area around filler cap.

– Clean area around fuel filler neck.


– Unscrew filler caps -1- and -2-.
– To prevent ingress of dirt, seal openings with a clean plug.
– Remove tank flap unit ⇒ General body repairs, exterior; Rep.
gr. 55; Tank flap unit; Removing and installing tank flap unit.
– Guide sealing grommet -1- out of filler pipes -arrows-.

– Pull sealing grommet -1- off body -2-, and remove it.
– Unscrew bolt -3-.

– Pull filler tube -1- towards outside off fuel tank bracket -2-.
– Place drip tray for workshop hoist -VAS 6208- underneath.
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.

578 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Detach breather line -3- and filler tube -2- from reducing
agent tank -1-.

– To do so, press release tabs -arrows-.


– Pull off filler tube and line.
– Pull out filler tube through opening in tank flap unit.
Installing
Install in reverse order of removal. While doing so, observe the
following:
– Fit filler tube -1- to guide of bracket -2-.

– Clean all components and connections with water and a


lint-free cloth.
– Remove reducing agent residue from connections.
– Fit filler tubes to reducing agent tank, and engage them.
– Push filler tube onto bracket as far as stop, and bolt it on.
– Make sure that filler tube is properly seated in guide of
bracket.
– Make sure that sealing grommet -1- is properly seated on
body -2- and filler tubes -arrows-.

3. SCR system (selective catalytic reduction) 579


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Specified torques:
♦ ⇒ o3.1 verview - tank for reducing agent”, page 530
♦ ⇒ Rep. gr. 20; Fuel tank; Assembly overview - fuel tank
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- rear wheel housing liner.
♦ ⇒ Running gear, axles, steering; Rep. gr. 44; Wheels, tyres;
Wheel change.
♦ ⇒ General body repairs, exterior; Rep. gr. 55; Tank flap unit;
Assembly overview – tank flap unit

3.13 Disconnecting reducing agent supply


line
Version 1 ⇒ Fig. ““Disconnecting reducing agent supply line,
version 1:”“, page 580
Version 2 ⇒ Fig. ““Disconnecting reducing agent supply line,
version 2:”“, page 582
Version 3 ⇒ Fig. ““Disconnecting reducing agent supply line,
version 3:”“, page 582
Disconnecting reducing agent supply line, version 1:

Releasing:
– Use water to clean area around securing clip.

580 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Place a cloth underneath coupling point to catch any escap‐


ing reducing agent.
– Push connector in opposite direction of -arrow 2-.
– Grasp connector on both sides, press together locking ele‐
ment, and keep it pressed.
– Press together securing clip of reducing agent line -1- in
-direction of arrow 1- as shown in illustration.
– Pull off delivery line in -direction of arrow 2- without tools and
without »jerking«.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Clean all components and connections with water and a
lint-free cloth.
Locking:

Note

♦ Note the different versions of the securing clip.


♦ The allocation depends on the type which is specified on the
plug-in connector.
♦ The different versions can be distinguished via the guide lug
-arrow-.
♦ The type is specified in area -1-.
♦ Refer to the table for allocating the securing clip ⇒ page
581 .
♦ Note the installation position of the securing clip.
♦ The securing clip must be installed as shown in the illustra‐
tion.
♦ If the securing clip/locking clip is not installed properly, the
connection cannot be released any more without being dam‐
aged.
♦ The mating connector may then be damaged.

Allocation of securing clip:

3. SCR system (selective catalytic reduction) 581


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Specification of type Allocation of securing clip


5/16 and 3/8 Securing clip 2 with guide lug
1/4 Securing clip 3
– Make sure that the connections are clean, and clean them
as necessary.
– Check connections for damage, and renew them as neces‐
sary.
– Push on line until it can be heard to engage.
– Check firm seating by pulling.
Disconnecting reducing agent supply line, version 2:

– Use water to clean area around locking element.


– Push connector in opposite direction in which it is pulled off.
– Press and hold locking element -arrows-.
– Pull off reducing agent line -2-.
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Clean all components and connections with water and a
lint-free cloth.
Locking:
– Make sure that the connections are clean, and clean them
as necessary.
– Check connections for damage, and renew them as neces‐
sary.
– Push on line until it can be heard to engage.
– Check firm seating by pulling.
Disconnecting reducing agent supply line, version 3:

582 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Use water to clean area around locking element.


– Push connector in opposite direction in which it is pulled off.
– Press and hold locking element -arrows-.
– Pull off reducing agent line -1-.
– Place a cloth underneath coupling point to catch any escap‐
ing reducing agent.
– Seal off all open lines and connections with clean plugs from
engine bung set -VAS 6122-.
– Clean all components and connections with water and a
lint-free cloth.
Locking:
– Make sure that the connections are clean, and clean them
as necessary.
– Check connections for damage, and renew them as neces‐
sary.
– Push on line until it can be heard to engage.
– Check firm seating by pulling.

3.14 SCR - resetting learnt values


The learnt value in the engine control unit must be re-adapted
using the vehicle diagnostic tester, if reducing agent has been
drained or if any of the following components have been re‐
newed:
♦ Reducing agent tank
♦ Pump for reducing agent
♦ Injector for reducing agent
♦ Line for reducing agent
♦ Engine control unit
Reset learnt values ⇒ Vehicle diagnostic tester.
Diagnosis-compatible systems
0001 - Engine electronics
0001 - Engine electronics functions
0001 - Adapting learnt values for SCR system

3. SCR system (selective catalytic reduction) 583


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

4 Exhaust gas temperature regulation


⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
⇒ a4.2 nd installing exhaust gas temperature sender 1G235”,
page 586
⇒ a4.3 nd installing exhaust gas temperature sender 2G448”,
page 592
⇒ a4.4 nd installing exhaust gas temperature sender 3G495”,
page 594
⇒ a4.5 nd installing exhaust gas temperature sender 4G648”,
page 595

4.1 Assembly overview – exhaust gas temperature regulation

Caution

Loose exhaust gas temperature senders cause malfunctions.


♦ Threads of exhaust gas temperature sender -G495- and
-G648- are coated. Do NOT additionally coat with high-
temperature paste and always adhere to the prescribed
specified torque.

584 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Connector for exhaust gas


temperature sender 1 -G235-
❑ Removing and instal‐
ling ⇒ page 584
❑ Coat with high-temper‐
ature paste; high-tem‐
perature paste ⇒ Elec‐
tronic Parts Catalogue.
❑ 45 Nm
2 - Lambda probe -G39- with
Lambda probe heater -Z19-
❑ Removing and instal‐
ling ⇒ page 494
3 - NOx sender control unit
-GX30-
❑ Comprises NOx sender
-G295- and control unit
for NOx sender -J583-
❑ Removing and instal‐
ling ⇒ page 471
4 - Exhaust gas temperature
sender 2 -G448-
❑ The thread of the ex‐
haust gas temperature
sender is coated and
must not also be coat‐
ed with high-tempera‐
ture paste.
❑ Removing and instal‐
ling ⇒ page 584
❑ 60 Nm
5 - Injector for reducing agent
-N474-
6 - Exhaust gas temperature
sender 3 -G495-
❑ Removing and installing ⇒ page 584
❑ The thread of the exhaust gas temperature sender is coated and must not also be coated with
high-temperature paste.
❑ 45 Nm
7 - Exhaust gas temperature sender 4 -G648-
❑ Removing and installing ⇒ page 584
❑ The thread of the exhaust gas temperature sender is coated and must not also be coated with
high-temperature paste.
❑ 60 Nm
8 - Exhaust gas temperature sender 1 -G235-
❑ Removing and installing ⇒ page 584
❑ Coat with high-temperature paste; high-temperature paste ⇒ Electronic Parts Catalogue.
❑ 45 Nm
9 - Bolt
❑ 8 Nm
10 - Pressure differential sender -G505-
❑ Removing and installing ⇒ page 466
11 - Centre hex stud

4. Exhaust gas temperature regulation 585


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
❑ 8 Nm
12 - Exhaust gas pressure sensor 1 -G450-
❑ Removing and installing ⇒ page 467
13 - Bolt
❑ 8 Nm
14 - Bolt
❑ 8 Nm
15 - Bracket
❑ For pressure differential sender

4.2 Removing and installing exhaust gas


temperature sender 1 -G235-
Special tools and workshop equipment required
♦ Tool set -T10395-

♦ Tool insert, 17 mm -T10395/11-


♦ Torque wrench -V.A.G 1331-

♦ Insert tool -T10572-

586 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Torx bit T30 -T10573-

♦ Torque wrench -V.A.G 1783-

♦ Engine support -T10533-

4. Exhaust gas temperature regulation 587


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Location

1- Connector ⇒ Item 1 (page 585)


2- Exhaust gas temperature sender 1 -G235- ⇒ Item 8 (page
585)
Removing

Note

♦ Attach cable ties in all the same places when installing.


♦ When removing, the wire must not be disconnected because
otherwise no troubleshooting is possible.

– Remove noise insulation ⇒ General body repairs, exterior;


Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Release and pull off connector -1- for oil level and oil tem‐
perature sender -G266-.

588 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -2- on auxiliary pump for


heating -V488-.
– To do this, open locking device -3- by pressing in direction of
-arrow- and release connector.
– Remove pendulum support ⇒ page 39 .
– Remove propshaft from bevel box ⇒ Propshaft and rear final
drive; Rep. gr. 39; Propshaft.
– Position engine support -T10533- -A- as shown.

– Engine support -T10533/2- -B- is positioned on flat bolt con‐


necting point of engine support -T10533/1-.
– Screw in original bolt of pendulum support -1- in front threa‐
ded hole of pendulum support.
– Screw bolt M8 × 60 mm -2- with washer into left threaded
hole of noise insulation.
– Between high bolt connecting point and subframe, engineer
a distance of 20 mm with washers -a-.
– Tighten bolts by hand.
– Using engine support -T10533-, push engine as far forwards
as possible.
– Ensure that there is sufficient clearance to all components.
– Remove exhaust gas temperature sender 4 -G648- ⇒ page
595 .

4. Exhaust gas temperature regulation 589


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows-.

– Use Torx bit T30 -T10573- to do this.


– Remove brackets -1- and -4-.
– Remove heat shield -2-.
– Unscrew bolts -arrows- to remove heat shield -1-.

– Carefully lever off heat shield at bolting points -arrows- using


a screwdriver.
– Detach exhaust gas temperature sender 1 -G235- -2- from
turbocharger using tool insert AF 17 -T10395/11-.

– Unscrew exhaust gas temperature sender 1 -G235- -2- on


turbocharger.

590 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Pull connection piece of exhaust gas temperature sender 1


-G235- -2- off bracket.
– Release connectors -1- and pull off.
– Lay wiring harness to one side.
– Remove exhaust temperature sender 1 -G235-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

Take care to protect exhaust gas temperature sender from


knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.

– Coat thread with high-temperature paste; high-temperature


paste ⇒ Electronic Parts Catalogue.
– Install heat shield -2- and bracket -1-.

– Align exhaust gas temperature sender 1 -G235-. To do this,


position angled cable guide in such a way that bracket -1-
can be bolted on free of stress.
– Remove heat shield -2- and bracket -1-.
– Tighten exhaust gas temperature sender 1 -G235- using tool
insert, 17 mm -T10395/11- and torque wrench -V.A.G 1331-.
– To do this, set torque wrench -V.A.G 1331- to 30 Nm.
– Install heat shield -2- and bracket -1-.
– Tighten bolts for heat shield with insert -T10572-, Torx bit
T30 -T10573- and torque wrench -V.A.G 1783-.
– Set torque wrench -V.A.G 1783- to 4.2 Nm.

4. Exhaust gas temperature regulation 591


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Specified torques

Note

♦ If tool insert, 17 mm -T10395/11- is used to tighten exhaust


temperature sender 1 -G235-, the torque wrench must be
set to 30 Nm.
♦ If insert -T10572- is used to tighten bolts for the heat shield,
the torque wrench must be set to 4.2 Nm.
♦ If a different tool is used, e.g. torque wrench accessories
-V.A.G 1410/1-, the values specified in the assembly over‐
view must be set.

♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page


584
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft

4.3 Removing and installing exhaust gas


temperature sender 2 -G448-
Special tools and workshop equipment required
♦ Tool set -T10395 A-

♦ Tool set supplement -T10395/8-/10-


♦ Lambda probe open ring spanner set -3337-

592 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Removing

Note

♦ Attach cable ties in all the same places when installing.


♦ When removing, the wire must not be disconnected because
otherwise no troubleshooting is possible.

– Remove engine cover panel ⇒ page 61 .


– Unclip, release and pull off corresponding connector ⇒ page
396 .
– Free off electrical wire.
– Mark position of exhaust gas temperature sender for later
installation.
– Use a suitable tool to unscrew exhaust gas temperature
sender 2 -G448- -5-.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Attach cable ties in all the same places when installing.


♦ Reinstall the heat insulation sleeves in the same place.
♦ Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.

Caution

Loose exhaust gas temperature senders cause malfunctions.


♦ Threads of exhaust gas temperature sender -G495- and
-G648- are coated. Do NOT additionally coat them with
high-temperature paste, and always adhere to the speci‐
fied torque.

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


carriers, electronics boxes; Overview of fitting locations -
relay carriers, fuse carriers, electronics boxes and ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.

4. Exhaust gas temperature regulation 593


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– The angled cable guide of the exhaust gas temperature


sender 2 -G448- must face towards injector for reducing
agent -N474-.
Specified torques
• ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
• ⇒ a3.1 nd installing engine cover”, page 61
• ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

4.4 Removing and installing exhaust gas


temperature sender 3 -G495-
Special tools and workshop equipment required
♦ Tool set -T10395 A-

♦ Tool set supplement -T10395/8-/10-


♦ Lambda probe open ring spanner set -3337-

Removing

Note

♦ Attach cable ties in all the same places when installing.


♦ When removing, the wire must not be disconnected because
otherwise no troubleshooting is possible.

– Remove engine cover panel ⇒ page 61 .


– Unclip, release and pull off corresponding connector ⇒ page
396 .
– Free off electrical wire.
– Mark position of exhaust gas temperature sender for later
installation.

594 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Use a suitable tool to unscrew exhaust gas temperature


sender 3 -G495- -5-.

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Attach cable ties in all the same places when installing.


♦ Reinstall the heat insulation sleeves in the same place.
♦ Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.

Caution

Loose exhaust gas temperature senders cause malfunctions.


♦ Threads of exhaust gas temperature sender -G495- and
-G648- are coated. Do NOT additionally coat them with
high-temperature paste, and always adhere to the speci‐
fied torque.

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


carriers, electronics boxes; Overview of fitting locations -
relay carriers, fuse carriers, electronics boxes and ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Specified torques
• ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
• ⇒ a3.1 nd installing engine cover”, page 61
• ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

4.5 Removing and installing exhaust gas


temperature sender 4 -G648-
Special tools and workshop equipment required

4. Exhaust gas temperature regulation 595


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Tool set -T10395 A-

♦ Tool set supplement -T10395/8-/10-


♦ Lambda probe open ring spanner set -3337-

Removing

Note

♦ Attach cable ties in all the same places when installing.


♦ When removing, the wire must not be disconnected because
otherwise no troubleshooting is possible.

– Remove engine cover panel ⇒ page 61 .


– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Unclip, release and pull off corresponding connector ⇒ page
396 .
– Mark position of exhaust gas temperature sender for later
installation.
– Use a suitable tool to unscrew exhaust gas temperature
sender 4 -G648- -1-.

596 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Attach cable ties in all the same places when installing.


♦ Reinstall the heat insulation sleeves in the same place.
♦ Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.

Caution

Loose exhaust gas temperature senders cause malfunctions.


♦ Threads of exhaust gas temperature sender -G495- and
-G648- are coated. Do NOT additionally coat them with
high-temperature paste, and always adhere to the speci‐
fied torque.

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


carriers, electronics boxes; Overview of fitting locations -
relay carriers, fuse carriers, electronics boxes and ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Specified torques
• ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
• ⇒ a3.1 nd installing engine cover”, page 61
• ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

4. Exhaust gas temperature regulation 597


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

5 Exhaust gas recirculation


⇒ o5.1 verview – exhaust gas recirculation”, page 598
⇒ a5.2 nd installing exhaust gas recirculation cooler”, page
601
⇒ a5.3 nd installing exhaust gas recirculation valve 1GX5”,
page 607
⇒ a5.4 nd installing exhaust gas recirculation valve 2GX6”,
page 609
⇒ e5.5 xhaust gas recirculation cooler for leaks”, page 612

5.1 Assembly overview – exhaust gas re‐


circulation
⇒ o5.1.1 verview – exhaust gas recirculation, exhaust gas recir‐
culation valve 2GX6”, page 598
⇒ o5.1.2 verview – exhaust gas recirculation, exhaust gas recir‐
culation valve 1GX5”, page 600

5.1.1 Assembly overview – exhaust gas recirculation, exhaust gas recirculation


valve 2 -GX6-

598 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Emission control module


❑ Removing and instal‐
ling ⇒ page 523
2 - Seal
❑ Renew after removal
3 - Screw-type clamp
❑ Renew after removal
❑ Observe installation po‐
sition. Clamp should
not be in contact with
components
❑ Specified torque and
tightening sequence: ⇒
page 600
4 - Exhaust gas recirculation
cooler
❑ Removing and instal‐
ling ⇒ page 601
❑ Check for leaks ⇒ page
612
5 - Bolt
❑ Specified torque and
tightening sequence: ⇒
page 600
6 - Bracket
❑ For exhaust gas recir‐
culation cooler
7 - Seal
❑ Renew after removal
8 - Exhaust gas recirculation
valve 2 -GX6-
❑ With exhaust gas recir‐
culation control motor 2 -V339-.
❑ With exhaust gas recirculation potentiometer 2 -G466-
❑ Removing and installing ⇒ page 609
9 - Bolt
❑ Qty. 3
❑ 9 Nm
10 - Retaining ring
11 - Seal
❑ Renew after removal
12 - Union
13 - Clip
14 - Hose
15 - Seal
❑ Renew after removal
16 - Bolt
❑ 9 Nm
17 - Connecting pipe

5. Exhaust gas recirculation 599


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

18 - Clip
19 - Bolt
❑ 9 Nm

Exhaust gas recirculation cooler - specified torque and tighten‐


ing sequence

– Tighten bolts in stages in the sequence shown.


Stage Bolts Specified torque
1 Screw-type 7 Nm
clamp -3-
2 -1, 2- Screw in by hand as far as stop
3 -1, 2- 20 Nm

5.1.2 Assembly overview – exhaust gas recirculation, exhaust gas recirculation


valve 1 -GX5-

600 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Coolant hoses
2 - Spring-type clip
3 - Exhaust gas recirculation
valve 1 -GX5-
❑ With exhaust gas recir‐
culation potentiometer -
G212-
❑ With exhaust gas recir‐
culation control motor -
V338-
❑ Removing and instal‐
ling ⇒ page 607
4 - Seal
❑ Renew after removal
5 - Seal
❑ Renew after removal
6 - Bolt
❑ 9 Nm

5.2 Removing and installing exhaust gas


recirculation cooler
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 6362-

5. Exhaust gas recirculation 601


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Bit XZN 10 -T10501-

♦ Engine support -T10533-

Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air filter ⇒ page 443 .
– Remove air pipe ⇒ page 382 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Release and pull off connector -1- for oil level and oil tem‐
perature sender -G266-.

602 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -2- on auxiliary pump for


heating -V488-.
– To do this, open locking device -3- by pressing in direction of
-arrow- and release connector.
Tiguan:

– Remove nuts -arrows B- from gearbox mounting -3-.


– Release and pull off coolant lines -4- from bracket -arrow A-.
– Remove bracket -1- from gearbox mounting -3-.
Passat and Arteon:

– Unscrew nuts -arrows-.

5. Exhaust gas recirculation 603


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove retainer -1- from water pipe -4- and gearbox mount‐
ing -3-.
Continued for all vehicles:

– Release retaining clips -arrows- and pull off both coolant


hoses -2- from water pipes -1-.
– Remove pendulum support ⇒ page 39 .
– Remove propshaft from bevel box ⇒ Propshaft and rear final
drive; Rep. gr. 39; Propshaft.
– Remove selector lever cable from gearbox ⇒ ; Rep. gr. 34;
Selector mechanism; Removing and installing selector lever
cable.
– Position engine support -T10533- -A- as shown.

– Engine support -T10533/2- -B- is positioned on flat bolt con‐


necting point of engine support -T10533/1-.
– Screw in original bolt of pendulum support -1- in front threa‐
ded hole of pendulum support.
– Screw bolt M8 × 60 mm -2- with washer into left threaded
hole of noise insulation.
– Between high bolt connecting point and subframe, engineer
a distance of 20 mm with washers -a-.
– Tighten bolts by hand.
– Push engine with engine support -T10533- forwards.
– Remove coolant pipe (rear) ⇒ page 310 .
– Remove left coolant pipe ⇒ page 308 .
– Removing and installing exhaust gas temperature sender 4
-G648- ⇒ page 595 .
– Remove exhaust gas recirculation valve 2 - GX6- ⇒ page
609 .

604 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove turbocharger 1 control unit - J724- ⇒ page 372 .


– Push engine further with engine support -T10533- as far
forwards as possible.
– Ensure that there is sufficient clearance to all components.
– Ensure that coolant hoses are not trapped between engine
and radiator.
– Unscrew bolts -arrows-, and remove water pipes -1-.

– Release clamps -2- and pull off coolant hoses -3-.


– If not yet connected, pull off coolant hose -2- from exhaust
gas recirculation cooler -1-. To do this, release retaining clip
-arrow-.

– Open clamp -4- and pull off coolant hose -3-.


– Place a cloth underneath heat exchanger for heater to catch
escaping coolant.

– Lift retaining clips -arrows- and disconnect coolant hoses


from heat exchanger for heater.
– Remove coolant hoses.

5. Exhaust gas recirculation 605


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolts -arrows- on rear of engine.

– Remove bottom left bracket -1-.


– Remove oil return line -1- for high-pressure turbocharger -3-.
To do this, unscrew bolts -2- ⇒ Item 10 (page 353) .

– Unscrew bolt -arrow- and remove oil return line.


– Open clip -3- and position it on intake funnel of emission
control module.

– Unscrew bolts -1-.


– Loosen bolt -2-.
– Pull exhaust gas recirculation cooler -4- towards left and
remove it downwards.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

606 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ Check heat insulation mat for damage and renew it if neces‐


sary.
♦ If the heat insulation mat is damaged, check the exhaust gas
recirculation valve 2 -GX6- for damage caused by heat, and
renew it if necessary.
♦ Renew seals, screw-type clip and hose clips after removal.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Insert exhaust gas recirculation cooler into emission control


module.

– Position clip -3- on intake funnel of emission control module.


– Mount bracket on engine and screw in bolt -1- loosely.
– Exhaust gas recirculation cooler must lie flat against emis‐
sion control module.
– Fit clamp -3- and insert bolt. Ensure that clamp is seated
correctly.
Specified torques
♦ ⇒ Fig. ““Exhaust gas recirculation cooler - specified torque
and tightening sequence”“, page 600
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o4.1 verview - air filter housing”, page 441
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o1.1.8 verview - oil lines on turbochargers”, page 352
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft

5.3 Removing and installing exhaust gas


recirculation valve 1 -GX5-
Special tools and workshop equipment required

5. Exhaust gas recirculation 607


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

♦ Hose clamps to 25 mm -3094-

The exhaust gas recirculation valve 1 -GX5- consists of:


♦ Exhaust gas recirculation potentiometer -G212-
♦ Exhaust gas recirculation control motor -V338-
Removing

– Remove throttle valve module -J338- ⇒ page 456 .


– Disconnect electrical connector -3-.
– Clamp off coolant hose with hose clamps up to 25 mm
-3094-.
– Release hose clip -2- and detach coolant hose.
– Unscrew bolts -arrows-, and remove exhaust gas recircula‐
tion valve 1 -GX5-.
Installing
Install in reverse order of removal, observing the following:

Note

♦ Renew seals.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

– Check coolant level ⇒ page 223 .


Specified torques
♦ ⇒ o5.1.2 verview – exhaust gas recirculation, exhaust gas
recirculation valve 1GX5”, page 600
♦ ⇒ o5.1 verview – intake manifold”, page 447

608 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

5.4 Removing and installing exhaust gas


recirculation valve 2 -GX6-
The exhaust gas recirculation valve 2 -GX6- consists of:
♦ Exhaust gas recirculation control motor 2 -V339-
♦ Exhaust gas recirculation potentiometer 2 -G466-
Special tools and workshop equipment required
♦ Torx bit T30 -T10573-

♦ Torque wrench accessories -V.A.G 1410/1-


♦ Torque wrench -V.A.G 1783-

Removing

Note

The exhaust gas recirculation control motor is protected against


damaged caused by heat with a heat insulation mat. If the insu‐
lation mat is damaged, renew it, and check the control motor
for damage caused by heat. Renew control motor as well, if
necessary.

– Remove engine cover panel ⇒ page 61 .


– Press release tabs on crankcase breather hose -4-, and
remove hose from intake hose -1-.

5. Exhaust gas recirculation 609


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– If fitted, release and pull off connector on hose -4-.


– Pull off vacuum hoses -2- and -3-.
– Release screw-type clips -5-, and pull off intake hose.
– Remove bolt -arrows-.

– Remove pipe -1- from turbocharger -2-.


– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– If fitted, remove noise insulation extension ⇒ General body
repairs, exterior; Rep. gr. 66; Noise insulation; Assembly
overview – noise insulation.
– Remove front exhaust pipe ⇒ page 501 .
– Unscrew nuts -arrows A- from rear coolant pipe.

610 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Push rear coolant pipe aside.


– Unscrew bolt -arrow A-.

– Unscrew bolt -3- on exhaust gas recirculation valve 2 -GX6-


-2-.

– Remove pipe -1- and place to one side.


– Open heat insulation sleeve -2- and remove.

5. Exhaust gas recirculation 611


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Release and pull off connector -3-.


– Unscrew bolts -4- and remove exhaust gas recirculation
valve 2 -GX6- -1-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew seal and O-ring after removal.


♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.

Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o1.1.1 verview - turbocharger”, page 341
♦ ⇒ o2.1 verview – emission control”, page 516

5.5 Checking exhaust gas recirculation


cooler for leaks
The exhaust gas recirculation cooler is checked for leaks using
⇒ Vehicle diagnostic tester. Connect ⇒ Vehicle diagnostic tester
to vehicle, and carry out the functional check Cooling system
leak tightness .
– Select own test
– Drive
– 0001 - Diesel engine
– Repair groups
– 19 - Cooling
– Cooling system leak tightness

Note

Depending on the vehicle, the engine and the firmware version


of the vehicle diagnostic tester, the specified path may vary
slightly.

612 Rep. gr.26 - Exhaust system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

6 Exhaust manifold
⇒ o6.1 verview - exhaust manifold”, page 613
⇒ a6.2 nd installing exhaust manifold”, page 614

6.1 Assembly overview - exhaust manifold

1 - Low-pressure turbocharg‐
er
❑ Assembly overview ⇒
page 341
2 - Exhaust manifold
❑ Removing and instal‐
ling ⇒ page 614
3 - Nut
❑ Specified torque and
tightening sequence: ⇒
page 613
4 - Seal
❑ Renew after removal
❑ Between exhaust mani‐
fold and high-pressure
turbocharger
5 - Bolt
❑ Qty. 2
❑ 10 Nm
6 - Heat shield
7 - Bolt
❑ 10 Nm
8 - Seal
❑ Renew after removal
9 - Stud
❑ 14 Nm

Turbocharger - specified torque and tightening sequence

6. Exhaust manifold 613


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Tighten bolts in stages in the sequence given:


Stage Bolts Specified torque
1 -Arrows- Tighten in the sequence -1- to -10- to
11 Nm.
2 -Arrows- Tighten in the sequence -1- to -10- to
22 Nm.
3 -Arrows- Tighten in the sequence -1- to -10- to
22 Nm.
• This procedure has been speci‐
fied in order to compensate for
the settling of the components.

6.2 Removing and installing exhaust mani‐


fold
– The exhaust manifold is removed together with the low-pres‐
sure turbocharger ⇒ page 354 .
– Unbolt low-pressure turbocharger from exhaust manifold ⇒
page 364 .
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:

Note

♦ Renew seals, gaskets, O-rings and self-locking nuts after


removal.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
♦ After installing turbocharger, run engine for about 1 minute
at idling speed to ensure that oil is supplied to turbocharger.
Do not rev engine immediately.
♦ After new components have been installed (engine/short en‐
gine, cylinder head, camshaft housing or turbocharger), the
oil pressure control must be set to max. pressure for approx.
1000 km. This will compensate for the increased friction
during run-in of new components, and a better transport
of wear-related particles is guaranteed. To do this, connect
vehicle diagnostic tester, switch on ignition, and select the
following menu options:
♦ Diagnosis-compatible systems
♦ 0001 - Engine electronics functions
♦ 0001 - Adaption
♦ Oil pressure control/activate run-in function

– Electrical connections and routing ⇒ Electrical system; Rep.


gr. 97; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, elec‐
tronics boxes and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.

614 Rep. gr.26 - Exhaust system


Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Passat 2015 ➤, Pass ...
4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Specified torques
♦ ⇒ o3.1 verview - coolant pipes”, page 294
♦ ⇒ o5.1 verview – exhaust gas recirculation”, page 598
♦ ⇒ o1.1 verview – silencers”, page 497
♦ ⇒ o1.7 verview - front exhaust pipe”, page 509
♦ ⇒ o4.1 verview – exhaust gas temperature regulation”, page
584
♦ ⇒ o2.1 verview – emission control”, page 516
♦ ⇒ o9.1 verview - Lambda probe”, page 494
♦ ⇒ o1.1 verview - turbocharger”, page 341
♦ ⇒ o2.1 verview - charge air system”, page 377
♦ ⇒ a6.2 nd installing exhaust manifold”, page 614
♦ ⇒ o1.2.2 verview - cylinder head cover with add-on parts”,
page 119
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ ⇒ o3.9 verview - injector for reducing agent”, page 566
♦ ⇒ o2.1 verview - assembly mountings”, page 29
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 323
♦ ⇒ o6.1 verview - exhaust manifold”, page 613
♦ ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carri‐
ers, electronics boxes; Overview of fitting locations - relay
carriers, fuse carriers, electronics boxes
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Lower suspen‐
sion link, swivel joint; Assembly overview – lower suspension
link, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Assembly overview - drive shaft
♦ ⇒ Rep. gr. 34; Bevel box; Assembly overview - bevel box
♦ ⇒ Propshaft and rear final drive; Rep. gr. 39; Propshaft

6. Exhaust manifold 615


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

28 – Glow plug system


1 Glow plug system
⇒ o1.1 verview - glow plug system”, page 616
⇒ a1.2 nd installing glow plug”, page 617
⇒ a1.3 nd installing automatic glow period control unitJ179”,
page 621
⇒ a1.4 nd installing Hall senderG40”, page 621
⇒ a1.5 nd installing engine speed senderG28”, page 622

1.1 Assembly overview - glow plug system

616 Rep. gr.28 - Glow plug system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1 - Hall sender -G40-


❑ Removing and instal‐
ling ⇒ page 621
2 - Bolt
❑ 9 Nm
3 - O-ring
❑ No replacement part.
Renew Hall sender if
damaged.
4 - Glow plug
♦ Glow plug 1 -Q10-
♦ Glow plug 2 -Q11-
♦ Glow plug 3 -Q12-
♦ Glow plug 4 -Q13-
❑ If fitted, glow plug
3 -Q12- with cylinder
3 combustion cham‐
ber pressure sender -
G679-
❑ Glow plug versions ⇒
page 618 .
❑ Removing and instal‐
ling ⇒ page 617
❑ Glow plug without com‐
bustion chamber pres‐
sure sender 17 Nm
❑ Glow plug with com‐
bustion chamber pres‐
sure sender 12 Nm
5 - Electrical connector
❑ For glow plug
6 - Sealing flange, gearbox side
❑ Removing and installing ⇒ page 85
7 - Sender wheel
❑ For engine speed sender -G28-
❑ Removing and installing ⇒ page 80
8 - Engine speed sender -G28-
❑ Removing and installing ⇒ page 622
9 - Bolt
❑ 4.5 Nm

1.2 Removing and installing glow plug


Special tools and workshop equipment required

1. Glow plug system 617


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♦ T-bar and socket, 10 mm -3220-

♦ Socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel -VAS


6454- for cylinder 3, if necessary

♦ Pliers -3314-

Removing
Glow plug versions

1- Glow plug with combustion chamber pressure sender -


only for cylinder 3, if fitted
2- Glow plug without combustion chamber pressure sender

618 Rep. gr.28 - Glow plug system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Remove engine cover panel ⇒ page 61 .

Caution

Risk of damage to support sleeves.


♦ Use pliers -3314- to remove glow plug connectors,
squeezing just enough to grasp the collar of the support
sleeve securely without damaging it.

– Release retaining clips at wiring harness and pull connectors


off glow plugs as follows:
– Position pliers -3314- with groove -arrow A- on support
sleeve shoulder -arrow B- as shown in illustration.

– Carefully detach glow plug connectors from glow plugs.


– Clean glow plug port in cylinder head.
– It must be ensured that no dirt falls into the cylinder when
this is being done.

Note

♦ Use a vacuum cleaner to remove coarse dirt.


♦ Spray brake cleaner or suitable cleaning agent into glow
plug port, let it work in briefly, and blow out with compressed
air.
♦ Then use a cloth moistened with oil to clean the glow plug
port.

WARNING

Risk of eye injury.


♦ Wear safety goggles.

– Loosen glow plugs using T-bar and socket, 10 mm -3220-


and unscrew them by hand.

1. Glow plug system 619


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

12 mm socket insert for glow plugs 4-cyl.TDI CR diesel -VAS


6454- for cylinder 3, if necessary

Installing
Install in reverse order of removal, observing the following:
– Fit glow plug connectors -1- back onto glow plugs -arrow-.

Note

Make sure that the glow plug connectors are firmly seated.

– Fit engine cover panel ⇒ page 61 .


Specified torques
♦ ⇒ o1.1 verview - glow plug system”, page 616

620 Rep. gr.28 - Glow plug system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

1.3 Removing and installing automatic


glow period control unit -J179-
Removing
– Release fasteners -arrows- and detach cover.

– Pull automatic glow period control unit -J179- -arrow- off slot
in electronics box in engine compartment.

Installing
Install in reverse order of removal.

1.4 Removing and installing Hall sender -


G40-
Removing
– Remove engine cover panel ⇒ page 61 .
– Remove bolts -arrows- and push fuel lines slightly towards
front.

– Disconnect electrical connector -2-.

1. Glow plug system 621


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

– Unscrew bolt -1- and detach Hall sender -G40-.


Installing
Install in reverse order of removal.
– Fit engine cover panel ⇒ page 61 .
Specified torques
♦ ⇒ o1.1 verview - glow plug system”, page 616

1.5 Removing and installing engine speed


sender -G28-
Special tools and workshop equipment required
♦ Assembly tool -T10118-

♦ Hexagon key extension, 4 mm -T10370-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Disconnect connector -1- using assembly tool -T10118-.

622 Rep. gr.28 - Glow plug system


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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021

Note

♦ Releasing connector without assembly tool -T10118-:


♦ Press in connector on engine speed sender with a screw‐
driver.
♦ At the same time lift release tab with a thin wire hook.

– Unscrew bolt -2- and detach engine speed sender -G28-.


Installing
Install in reverse order of removal.
Specified torques
♦ ⇒ o1.1 verview - glow plug system”, page 616
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation

1. Glow plug system 623

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