Engine Cuaa Repair Manual Eng
Engine Cuaa Repair Manual Eng
Engine Cuaa Repair Manual Eng
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
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.
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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
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
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
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
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
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
Contents iii
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
iv Contents
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Contents v
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
vi Contents
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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
WARNING
1. Safety information 1
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
1.3 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.
WARNING
1. Safety information 3
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Caution
2 Identification
⇒ n2.1 umber/engine data”, page 5
Note
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
Codes CUAA
Lambda regulation 1 lambda probe
Diesel particulate filter with catalytic converter yes
SCR catalytic converter yes
Valves per cylinder 4
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
Note
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.
Caution
Note
WARNING
– 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
Note
For the work steps below use removal lever -80 - 200- to unclip
the binding clips.
– 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.
Caution
Procedure
Note
Note
WARNING
Caution
Note
Specified torques
Component Nm
Bolts and nuts M6 10
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
Note
Note
Note
The bolts are tightened to final torque only after adjusting the
assembly mountings ⇒ page 57 .
Note
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. 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
Note
Renew bolts that are tightened with turning further angle after
each removal.
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
Note
Renew bolts that are tightened with turning further angle after
each removal.
2. Assembly mountings 33
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
– 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
Note
2. Assembly mountings 35
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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-.
– 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.
Caution
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-.
Note
Renew bolts that are tightened with turning further angle after
each removal.
Caution
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
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.
♦ Adapter -10-222A/1-
♦ Joints -T40091/3-
♦ Support -T40093/3-
♦ Adapter -T40093/3-6A-
2. Assembly mountings 41
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2. Assembly mountings 43
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
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-
2. Assembly mountings 45
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Note
– Unclip retainer.
– Remove foam elements -arrows- for plenum chamber seal
on left and right.
2. Assembly mountings 47
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Note
Caution
2. Assembly mountings 49
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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-
♦ Adapter -10-222A/8-
Note
2. Assembly mountings 53
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2. Assembly mountings 55
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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-
2. Assembly mountings 57
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Note
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
Note
Caution
– 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.
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 - 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
Note
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
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
Note
Renew bolts that are tightened with turning further angle after
each removal.
Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 62
Note
Removing
Note
Renew bolts that are tightened with turning further angle after
each removal.
Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 62
Note
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
Note
To remove bolts -1- and -2-, the engine support must first be
removed.
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.
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.
♦ 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-.
Caution
Note
Note
♦ Puller -T10055-
Note
Set the spot weld only on the outside of the nut to make sure
that the threads remain undamaged.
1 - Flywheel
❑ Removing and instal‐
ling ⇒ page 83
❑ Can only be fitted in
one position
Note
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
Removing
• Gearbox is removed.
Caution
Installing
Install in reverse order of removal, observing the following:
Caution
Caution
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 80
♦ 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
• 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
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
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-:
– 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-.
– 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.
Note
Set the spot weld only on the outside of the nut to make sure
that the threads remain undamaged.
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
WARNING
3. Crankshaft 97
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Note
Prerequisites:
– 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
3. Crankshaft 99
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4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Note
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-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288) - Edition 02.2021
Note
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
Caution
Caution
Note
Note
Note
Procedure
1- Part number
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.
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.
Note
Note
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
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
Note
Note
1- Part number
2- Ignore
3- Holes
Note
Note
Renew bolts that are tightened with turning further angle after
each removal.
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
16 - Bolt
❑ Renew gasket if damaged
❑ Specified torque and tightening sequence: ⇒ page 119
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
Removing
Note
Note
Caution
Installing
Install in reverse order of removal, observing the following:
Note
1- Part number
2- Ignore
3- Holes
Note
Note
Caution
Note
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
Removing
Note
Caution
– 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.
Note
♦ Renew O-ring.
♦ Renew gasket and bolts for cylinder head cover if damaged
or leaking.
♦ Yoke -3390-
Procedure
– Remove corresponding injector ⇒ page 417 .
– Twist oil seal extractor -T40195- into oil seal -1-.
Note
Removing
– Remove air pipe ⇒ page 382 .
– Unscrew bolt -3- and move bracket -2- aside.
Caution
WARNING
Note
Caution
Note
Caution
Note
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
Procedure
Note
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
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°
– 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-.
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
Caution
Carry out the following work step with particular care. If the
toothed belt is damaged, damage to the engine may result.
♦ 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.
Note
– Fit toothed belt guard. Note dowel pin -arrow- while doing
so.
Specified torques
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ Counterhold -T10051-
Note
Removing
– Remove upper part of toothed belt guard ⇒ page 140 .
– Remove engine support ⇒ page 72 .
– Remove lower toothed belt guard ⇒ page 144 .
Caution
Caution
– Pull out locking pin, and slightly loosen bolt for camshaft.
Before loosening completely, insert locking pin back in.
– Loosen bolt -arrow- for camshaft pulley.
– 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.
Caution
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Note
Note
For adjusting work on the toothed belt, the engine must be cold.
Caution
Prerequisites:
Note
Caution
The locking bolt must not lie against upper stop of elongated
hole after toothed belt has been tensioned.
• 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.
Note
Caution
Caution
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:
Caution
– 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) .
Note
♦ Renew seals.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
Specified torques
♦ ⇒ o2.2 verview - toothed belt”, page 138
♦ ⇒ o2.1 verview - toothed belt cover”, page 138
♦ Counterhold -T10051-
Note
Removing
– Remove upper part of toothed belt guard ⇒ page 140 .
– Remove vibration damper ⇒ page 69 .
Caution
Note
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
Caution
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
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
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.
2 -1 to 15- 10 Nm
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
Procedure
– Remove toothed belt from camshaft ⇒ page 161 .
Caution
Note
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
Note
– Press oil seal in onto stop using press tool -T10493/2- and
bolt -T10493/3-.
Note
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
Procedure
– Remove camshaft housing ⇒ page 131 .
– Mark allocation of roller rocker fingers -1-, hydraulic compen‐
sation element -4- and valves -3- for reinstallation.
Note
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
– 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-.
– 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 .
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.
Note
– 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.
Procedure
Note
– Attach dial gauge -VAS 6079- with universal dial gauge hold‐
er -VW 387- to cylinder head.
Note
Note
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
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 .
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
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
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-.
Installing
Caution
WARNING
Note
Caution
Note
Note
Caution
Caution
Installing
Install in reverse order of removal, observing the following:
Note
– 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
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 .
Note
Renew bolts that are tightened with turning further angle after
each removal.
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and pull off connector -arrow-.
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
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
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.
Removing
– Remove air filter housing ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
– Attach protective mat -VAS 531003- to vehicle as shown in
illustration.
– Release and pull off connector -1- on valve for oil pressure
control -N428-.
Note
Caution
WARNING
Note
– Unscrew bolt -2- and remove valve for oil pressure control
-N428-.
Installing
Install in reverse order of removal, observing the following:
Note
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
Note
Note
Note
WARNING
– 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-.
– 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-.
Note
♦ Safety glasses
♦ Safety gloves
Filling
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
Procedure
– Re-connect all coolant hoses that were pulled off.
Coolant specifications
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.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
Note
♦ If the needle does not reach the green zone, repeat the
process.
♦ If the vacuum drops, check the cooling system for leaks.
Note
Note
♦ Refractometer -T10007B-
Caution
Coolant specifications
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.
Caution
– 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:
Prerequisites:
• Needle on pressure gauge -arrow- must clearly be below
green area.
– »Slowly« open shut-off tap -A- to prevent coolant from foam‐
ing.
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.
Note
Note
– 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.
Note
Condition
• Ignition off
• Coolant temperature between 40°C and 60°C
– Open filler cap -arrow- for coolant expansion tank.
♦ 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.
Note
Note
Do not fit the valve block onto the test adapter -VAS 691 005/5-.
The filler hose must be bled first.
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 .
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.
Note
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.
– 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-.
Note
Use the extraction adapter ⇒ Item 14 (page 240) to extract the coolant.
Note
Note
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.
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 .
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
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
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°
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
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
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
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
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
Removing
– Open cap -1- on coolant expansion tank.
WARNING
Note
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.
Note
WARNING
Note
Note
Note
Note
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-.
Installing
Install in reverse order of removal, observing the following:
Note
Note
Note
Note
WARNING
Note
Note
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
WARNING
Note
Note
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
WARNING
Note
Note
WARNING
Note
Note
3 Coolant pipes
⇒ o3.1 verview - coolant pipes”, page 294
⇒ a3.2 nd installing coolant pipes”, page 298
Note
The arrow markings on coolant pipes and on ends of coolant hoses must align.
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
29 - Hose clamp
30 - Union
Removing
– Remove engine cover panel ⇒ page 61 .
– 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-.
Note
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 .
– 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.
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.
Note
Removing
– Remove intake manifold ⇒ page 450 .
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
Removing
– Remove engine cover panel ⇒ page 61 .
– Drain coolant ⇒ page 213 .
– Remove air duct ⇒ page 443 .
– Remove radiator cowl ⇒ page 333 .
Note
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.
Note
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-.
– Pull coolant hose -2- off exhaust gas recirculation cooler -1-.
– Unscrew bolts -arrows A- to remove connection -1-.
Note
Removing
– Open cap -1- on coolant expansion tank.
WARNING
– Drain coolant.
– Unscrew nuts -arrows A-.
– Open clips -arrows B-, and pull coolant hoses -2- off coolant
pipe -1-.
Note
Removing
– Remove emission control module ⇒ page 523 .
– 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
Removing
– Remove engine cover panel ⇒ page 61 .
– Open filler cap -5- on coolant expansion tank.
Caution
– Open clip -A- and pull coolant hose off water pipe -1-.
– Unscrew bolts -arrows- for coolant pipe -1-.
Removing
– Remove engine cover panel ⇒ page 61 .
– Open filler cap -5- on coolant expansion tank.
Caution
– 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
– Ensure that coolant pipe -2- sits in front of coolant pipe -1-
as shown.
Note
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.
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
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
Arteon:
Note
Caution
– Unclip air ducts -1- on both sides from lock carrier -2-
-arrows- and push to one side.
Note
Note
– 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).
Caution
WARNING
Note
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
WARNING
Note
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
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-.
– 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-.
Note
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. 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
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. 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 - 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. 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
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
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
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 - 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
Caution
♦ Bits -T10099-
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
Removing
Note
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
Note
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
Caution
Removing
Note
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.
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
Note
1. Turbocharger 365
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 367
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
– 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
Removing
Fitting location ⇒ Item 19 (page 348) :
1. Turbocharger 369
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 371
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
1. Turbocharger 373
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
Note
Use new bolts and a new circlip from the repair kit.
1. Turbocharger 375
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
Note
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
Caution
Note
If there is water in the inspection glass -6-, drain it via the drain
plug.
Note
Installing
Assemble in reverse order of dismantling.
Specified torques
♦ ⇒ o4.1 verview - air filter housing”, page 441
Tiguan:
– 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
Note
Test specification:
• Coolant temperature must be at least 40 °C.
Connecting turbocharger tester -V.A.G 1397A-:
Caution
Note
If there is water in the inspection glass -6-, drain it via the drain
plug.
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.
Note
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.
Note
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
Note
View 2:
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
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-
Caution
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.
2 Vacuum system
⇒ d2.1 iagram - vacuum system”, page 412
⇒ v2.2 acuum system”, page 415
Pfeile A - Bolt, 8 Nm
Pfeil B - Bracket
To remove, remove from lower part -1- of intake manifold ⇒
page 450 :
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)
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.
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
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.
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
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.
Cylinders 3 and 4:
Note
Caution
Note
If the engine cannot be started, the return flow rate of the injec‐
tors can also be checked at starter motor speed.
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.
Note
♦ 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«.
Note
To avoid damaging the sealing lip, rotate the injector while pull‐
ing it out.
Caution
♦ 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.
– Clean fuel line and head of line using cold cleaning solvent
and dry using compressed air.
– Unscrew bolt -6-.
Specified torques
♦ ⇒ o3.2 verview - fuel rail”, page 419
♦ ⇒ o8.1 verview - high-pressure pump”, page 488
♦ Socket -T40055-
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
– 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-.
4 Air filter
⇒ o4.1 verview - air filter housing”, page 441
⇒ a4.2 nd installing air filter housing”, page 443
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.
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
– Pull air duct -1- off air filter -2- on connection -arrow-.
Removing air filter housing:
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
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
Caution
Note
Intake manifold and charge air cooler are combined as one unit.
– 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-.
– Open clips, and pull coolant hoses -arrows- off coolant pipe
-1-.
Note
– Pull off coolant pipe -2- from intake manifold -1- and push to
one side.
– Loosen clamps -arrow-.
– 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
Caution
Note
Removing
– Remove engine cover panel ⇒ page 61 .
– Release and unplug electrical connector -2-.
Note
Note
– Release hose clip -arrow- and detach fuel return hose from
high-pressure reservoir.
– Seal open return line connection with a blanking plug.
Caution
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-.
Note
Note
– 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.
– 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
Note
Caution
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.
Note
Removing
– Remove engine cover panel ⇒ page 61 .
– Open heat insulation sleeve -1-.
Caution
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.
WARNING
♦ Socket 22 mm -T10491-
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.
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
♦ Socket 22 mm -T10491-
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.
– 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
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-.
Note
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.
Note
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.
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.
WARNING
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.
WARNING
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.
8 High-pressure pump
⇒ o8.1 verview - high-pressure pump”, page 488
⇒ a8.2 nd installing high-pressure pump”, page 490
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 .
13 - Hub
❑ To remove, use puller -T10489-
♦ Puller -T10489-
Removing
Caution
Caution
9 Lambda probe
⇒ o9.1 verview - Lambda probe”, page 494
⇒ a9.2 nd installing Lambda probe”, page 494
♦ 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.
Installing
Install in reverse order of removal, observing the following:
Note
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
17 - Bolt
❑ 20 Nm
18 - Retaining loop
❑ Renew if damaged
19 - Bracket
20 - Bolt
❑ 20 Nm
Variante A - 25 Nm
Variante B - 30 Nm
Tighten threaded connections evenly.
Align exhaust system free of tension before tightening ⇒ page
508 .
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
Variante A - 25 Nm
Variante B - 30 Nm
Tighten threaded connections evenly.
Align exhaust system free of tension before tightening ⇒ page
508 .
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release and unplug electrical connector -1-.
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.
Note
Removing
– Remove rear tunnel cross-piece ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding.
WARNING
WARNING
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
Note
1.7.3 Assembly overview - front exhaust pipe, vehicles with control unit 2 for
NOx sender -GX46- and particulate sensor -G784-
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
18 - Subframe
❑ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; Assembly overview - subframe
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
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.
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:
Note
– 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.
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
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
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.
– 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-.
Note
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
Removing
WARNING
– 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.
– 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.
Note
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:
– 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.
– 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.
– 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.
– If fitted, clip reducing agent supply line into retaining clip for
the lines.
– Attach connectors -3- to supply line as shown in illustration.
Note
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.
WARNING
– 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.
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.
– If fitted, clip reducing agent supply line into retaining clip for
the lines.
Note
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-.
Note
Note
There are letters indicated on the supply unit at the 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
♦ ⇒ o3.3 verview - delivery module for reducing agent”, page
535
Note
– 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
Draining
Note
WARNING
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.
Note
Caution
Note
WARNING
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.
Note
Caution
– 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.
– 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.
– Detach breather line -3- and filler tube -2- from reducing
agent tank -1-.
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
Releasing:
– Use water to clean area around securing clip.
Note
Caution
Location
Note
Note
Specified torques
Note
Removing
Note
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
Caution
Removing
Note
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
Caution
Removing
Note
Installing
Install in reverse order of removal. During this procedure, ob‐
serve the following:
Note
Caution
18 - Clip
19 - Bolt
❑ 9 Nm
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
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-.
– Remove retainer -1- from water pipe -4- and gearbox mount‐
ing -3-.
Continued for all vehicles:
Note
Note
♦ Renew seals.
♦ Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
Removing
Note
Note
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
Note
6 Exhaust manifold
⇒ o6.1 verview - exhaust manifold”, page 613
⇒ a6.2 nd installing exhaust manifold”, page 614
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
Note
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
♦ Pliers -3314-
Removing
Glow plug versions
Caution
Note
WARNING
Note
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.
– Pull automatic glow period control unit -J179- -arrow- off slot
in electronics box in engine compartment.
Installing
Install in reverse order of removal.
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Disconnect connector -1- using assembly tool -T10118-.
Note