VW-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

Service
Workshop Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system n AG. Volkswagen AG do
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28 - Glow plug system by Vo lk ot g
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D3E80219C61

California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ➤ , Transporter 20 ...
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 08.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 To avoid any risk of injuries to persons and/or the destruction of the injection and glow plug
system, the following must be noted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Rules for cleanliness during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Rules for cleanliness when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Removing and installing engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Modifying engine bracket T10229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5 Converting adapter 10 - 222 A /23 with adapter 10 - 222 A /23-1 . . . . . . . . . . . . . . . . . . . . 30
2 Assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Assembly overview - assembly mountings ......................................
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2.3 Removing and installing d motor mounting . . . . . . . . . . . . u.a.ra. . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Removing and installing
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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1.3 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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1.4 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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1.5 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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1.6 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.7 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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1.8 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1.9 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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3 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Contents
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.6 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.7 Renewing spur gear for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.5 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.6 Checking hydraulic compensation elements . . . . . . . . . . . e.n.A.G.. V. o.lk.s.w.a.ge.n.A.G. . . . . . . . . . . . 148
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3.7 Removing and installing valve stem seals . . . . . . . V. o.lk.sw . . . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . 148
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . .o.ris.e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . 153
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4.1 Reworking valve seats . . . . . . . . . . . . . . .au.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or a153 c
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4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ce
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4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 166
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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

2.2 Removing and installing oil filter housing with engine oil cooler “single turbo engine” . . . . 169
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2.3 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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2.4 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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3.1 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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3.2 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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3.3 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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4.1 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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ii Contents
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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1.1 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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1.3 Assembly overview - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.4 Connection diagram for coolant hoses - vehicles with basic equipment . . . . . . . . . . . . . . 195
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Connection diagram for coolant hoses - vehicles with additional heat exchanger . . . . . . . . 197
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1.6 Connection diagram for coolant hoses - vehicles with auxiliary heater . . . . . . . . . . . . . . . . 201
1.7 Connection diagram for coolant hoses - vehicles with additional heat exchanger and auxiliary
heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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1.8 Connection diagram for coolant hoses - vehicles with basic equipment from week 45/10
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1.9 Connection diagram for coolant hoses - vehicles with additional heat exchanger from week
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45/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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1.10 Connection diagram for coolant hoses - vehicles with auxiliary heater from week 45/10 . . 215
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1.11 Connection diagram for coolant hoses - vehicles with additional heat exchanger and
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supplementary heater from week 45/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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2.1 Assembly overview - coolant pump and ball thermostat (4/2-way valve) . . . . . . . . . . . . . . 223
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2.2 Assembly overview - Continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . 224

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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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2.4 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 226
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2.5 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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2.6 Removing and installing Y-thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 232
2.8 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 234
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3.1 Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.4 Removing and installing radiator cowl with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . 245
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.1 Procedure when filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.1 Assembly overview - supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.2 Removing and installing supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.3 Checking supplementary fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.4 Checking delivery pressure of fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . 264
4.5 Checking fuel delivery rate of fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . 266
4.6 Checking voltage supply of fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . 267
4.7 Checking current draw of fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . 269
5 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.1 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.2 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Contents iii
. Volkswag
1.1 Assembly overview - turbocharger ks.w.a.ge. n.A.G. . . . . . . .en. A. G . .do. e.s. . . . . . . . . . . . . . . . . . . . . . . . 273
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1.2 Assembly overview – connecting d by Vpipes (bi-turbo) . . . . . . . . . . .t g.u.a . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing turbocharger
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1.4 Removing and installing au
ss exhaust manifold gasket (bi-turbo) . . . . . . . . . . c. . . . . . . . . . . . . . 311
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1.5 Removing and installing compressor housing and turbine housing (bi-turbo) . . . . . . . . . . 319
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1.6 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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1.7 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.8 Removing and installing connecting pipes (bi-turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
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2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
2.4 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
...................................................................... 354
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2.5 Removing and installing exhaust gas flap valve N220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
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2.6 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . 356
2.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
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2.8 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 361

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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
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1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

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1.2 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

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1.3 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
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1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
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2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
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2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
AG.
2.2 Checking vacuum system for leaks, “bi-turbo engine” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

2.3 Checking vacuum system for leaks, “single turbo engine” . . . . . . . . . . . . . . . . . . . . . . . . 391
2.4 Checking vacuum system for leaks, “four-wheel drive” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3.1 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3.2 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3.4 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
3.5 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3.6 Check pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3.7 Checking low pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
3.8 Checking fuel pump delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
5.3 Removing and installing throttle valve module J338 with throttle valve potentiometer G69 and
intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
6.2 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 444
6.3 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
6.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
6.5 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 450
7 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
7.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 453
iv Contents
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

8.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
1.3 Separating exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
1.4 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
1.5 Aligning exhaust system free of stress . . . . . . . .en. A. G. ..V.ol.ks. w. a.g.en. A. G. . . . . . . . . . . . . . . . . . . . 465
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2 Exhaust gas cleaning . . . . . . . . . . o.ris. e.d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an. te. . . . . . . . . . 467
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2.1 Assembly overview - particulate filter
au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a.c . . . . . . 467
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2.2 Assembly overview - catalytic converter,
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four-wheel drive vehicles . . . . . . . . . . . . . . . . . . 472
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2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
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2.4 Removing and installing catalytic converter, four-wheel drive vehicles . . . . . . . . . . . . . . . . 479
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3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
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3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
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3.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 485
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3.3 Removing and installing exhaust gas recirculation valve N18 with exhaust gas recirculation
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potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
3.4 Pressure loss test for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
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1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
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1.3 Checking glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
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1.4 Optical characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

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1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
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1.6 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

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⇒ “1.1 Safety regulations for working on fuel supply”, page 1
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⇒ “1.2 Safety precautions when working on charge air system”,
page 2
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⇒ “1.3 Safety precautions when working on injection system”,
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⇒ “1.4 Safety precautions when working on the cooling system”,

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⇒ “1.5 To avoid any risk of injuries to persons and/or the destruc‐

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Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all kinds of lines (e.g. for fuel, hydraulics, activated
charcoal system, coolant and refrigerant, brake fluid, vac‐
uum) and electrical cables so that the original line routing
is re-established.
♦ Make sure there is adequate clearance from all moving or
hot parts.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place a cloth around the connection and re‐
duce pressure by carefully loosening the connection!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used (providing that motor is not in air flow).
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1. Safety information 1
1.2 Safety precautions when working on

charge air system
WARNING
Please observe the following points during all installation work,

in particular in the engine compartment, due to the space AGlim‐
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Note the following if testers and measuring instruments have to
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♦ Test equipment must always be secured on the rear seat and
operated by a 2nd person.
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If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
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injuries when the airbag is triggered.
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1.3 Safety precautions when working on in‐

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hot parts.
Note
The diesel direct injection system control unit is equipped with an

event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester.

♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
2 Rep. gr.00 - Technical data

♦ The ignition must be switched off before connecting or dis‐

connecting preglow and injection system wiring as well as test
equipment leads.
♦ Before disconnecting battery, obtain radio code for radios with en AG. Volkswagen AG
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unit for eo
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diesel direction injection system could become ss damaged. c
ce
le
un
pt
1.4 Safety precautions when working on the
an
d
itte
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cooling system
rm
ab
pe
ility
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WARNING hole
spec
es, in part or in w
The cooling system is under pressure when the engine is hot!
t to the co
Risk of scalding due to steam and hot coolant.
Reduce excess pressure by covering the cap of the coolant
rrectness of i
expansion tank with cloths and opening it carefully.
l purpos
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ercia
Caution
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Danger of overheating due to incorrectly fitted cap!
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♦ Tighten cap of coolant expansion tank until it engages.
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1.5 To avoid any risk of injuries to persons
Co
Cop py
t. rig
and/or the destruction of the injection
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pyri by
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and glow plug system, the following
c by lksw
cted agen
Prote AG.
must be noted
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Always switch off ignition before cleaning engine.
♦ The battery should only be disconnected and reconnected
with ignition switched off.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all checks and re‐
pairs, the fault memory must be read and if necessary cleared.
1.6 Safety precautions when using testers

and measuring instruments during a
road test
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
1. Safety information 3
♦ Operating from the front passenger seat may result in an ac‐

cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.
AG. Volkswagen AG d
agen oes
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rise nte
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nl
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spec
es, in part or in w
t to the co
rrectness of i
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olkswagen AG
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California 2010 ➤ , Caravelle 2010olks ➤ , Multivan 2010 ➤ , Transporter
does
not 20 ...
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4-cylinder diesel engine
sed b (2.0 l engine, common rail) - Edition
ara 08.2016
n ri tee
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2 Identification
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⇒ “2.1 Engine number/engine data”, page 5
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2.1 Engine number/engine data
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The first 3 digits refer to the mechanical configuration of the en‐
hole
spec
gine. They are stamped onto the engine. The fourth digit shows
es, in part or in w
the engine output and varies according to engine control unit. The
t to the co
four-digit engine code can be found on the identification plate, the
vehicle data sticker and the engine control unit.
rrectness of i
The engine number (“engine code” and “serial number”) can be
found at the joint between engine and gearbox -arrow-. l purpos
In addition, there is a sticker attached to the toothed belt guard

showing the “engine code” and “serial number”.
nf
ercia
or
The engine code is also included on the vehicle data sticker.
m
m
atio
m
The engine number consists of up to nine characters (alphanu‐

o
n in
or c
meric). The first part (maximum 4 characters) makes up the
thi
te
“engine code”, and the second part (6 characters), the “serial
sd
iva
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number”. If more than 999,999 engines were produced with the

rp
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same code letters, the first of the six digits is replaced by a letter.
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Identification code CAAA CAAB CAAC CAAE
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Manufactured from 05.09 ► 05.09 ► 05.09 ► 05.10 ►
to
Exhaust emissions fulfil EU4 standard EU3 standard EU5 standard EU5 standard
EU5 standard EU4 standard
EU5 standard
Displacement l 2.0 2.0 2.0 2.0
Power kW at rpm 62/3500 75/3500 103/3500 100/3500
Torque Nm at rpm 220/ 250/ 340/ 340/
1250 - 2500 1500 - 2500 1750 - 2500 1750 - 2500
Displacement cm3 1968 1968 1968 1968
Bore Diameter, 81.0 81.0 81.0 81.0
mm
Stroke mm 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4
Compression ratio 16.5 16.5 16.5 16.5
Fuel acc. to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module No No No No
Catalytic converter Yes Yes Yes Yes
Exhaust gas recirculation Yes Yes Yes Yes
Charging Yes Yes Yes Yes
Intercooler Yes Yes Yes Yes
particulate filter yes, for EU5 yes, for EU5 yes, for EU5 yes, for EU5
particulate filter no, for EU4 no, for EU3 and No —
EU4
Selective catalytic reduction No No No No
(SCR system)
2. Identification 5
Identification code CCHA CCHB CFCA CAAD

Manufactured from 05.09 ► 05.10 ► 05.09 ► 05.11 ►
to
Exhaust emissions fulfil EU5 standard EU5 standard EU5 standard EU5 standard
Displacement l 2.0 2.0 2.0 2.0
Power kW at rpm 103/3500 100/3500 132/4000 84/3500
Torque Nm at rpm 340/ 340/ 400/ 250/
1750 - 2500 1750 - 2500 1500 - 2000 1500 - 2500
Displacement cm3 1968 1968 1968 1968
Bore Diameter, 81.0 81.0 81.0 81.0
mm
Stroke mm 95.5 95.5 95.5 95.5
Volkswagen AG
Valves per cylinder 4 4 wage
n AG .
4 does 4
olks not
Compression ratio 16.5 16.5
d byV 16.5 gu 16.5
ara
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Fuel acc. to DIN EN 590 uthDIN
or EN 590 DIN EN 590 DIN ENtee590
or
a a
Firing order 1-3-4-2 ss 1-3-4-2 1-3-4-2 1-3-4-2 c
ce
e
nl
Balancer shaft module Yes Yes Yes No
pt
du
an
itte
Catalytic converter Yes Yes Yes Yes
y li
erm
ab
Exhaust gas recirculation Yes Yes Yes Yes
ility
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wit
Charging Yes Yes Yes Yes
, is n
h re
hole
Intercooler Yes Yes Yes Yes
spec
es, in part or in w
particulate filter yes, for EU5 yes, for EU5 yes, for EU5 yes, for EU5
t to the co
particulate filter — — no, for EU3 and —
EU4
rrectness of i
Selective catalytic reduction No No No No
(SCR system)
l purpos
nf
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Prote AG.

3 Repair notes
⇒ “3.1 General notes on the lubrication system”, page 7
⇒ “3.2 General notes on fuel system”, page 7
⇒ “3.3 Instructions for working on fuel system”, page 8
⇒ “3.4 Rules for cleanliness when working on fuel supply system”,
page 9
Volkswagen AG
⇒ “3.5 Rules for cleanliness during work on fuel asystem”,
gen AG
.
does
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page 10 by
Vol not
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⇒ “3.6 Rules for cleanliness when working
ho
ri on injection system”, eo
ut
page 10 ss a ra
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3.1 General notes on the lubrication system

un
pt
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Note
wit
is n
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ole,
The oil level must remain below the max. mark - danger of dam‐
spec
age to catalytic converter!
t to the co
Caution
rrectne
Finding metal shavings or a large quantity of small metal par‐
s
ticles during engine repair could indicate that the crankshaft
s o
bearings or conrod bearings are damaged. To prevent this
cial p
f in
from causing further damage, perform the following repairs:
form
mer
♦ Thoroughly clean oil passages,
atio
om
n
c
i
♦ Renew oil spray jets,
or
n thi
te
sd
a
♦ Renew engine oil cooler,

iv
o
pr
cum
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fo
♦ Renew oil filter element.

en
ng
t.
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Cop py
t. rig
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yri by
3.2 General notes on fuel system
op Vo
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cted agen
Prote AG.
Caution

in particular in the engine compartment, due to the space lim‐
itations:
is re-established.
hot parts.
3. Repair notes 7
AG. Volkswagen AG d
agen oes
olksw not
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Note ss a c
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un
pt
♦ Cooling system is pressurized when engine is warm. If nec‐
an
d
itte
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essary, release pressure before carrying out repairs.
erm
ab
ility
ot p
♦ Hose connections are secured with spring-type clips. In case
wit
of repair, only use spring-type clips.
is n
h re
ole,
♦ For fitting spring-type clips, hose clip pliers - VAS 6340- or
spec
♦ hose clip pliers - VAS 6362- are recommended.
t to the co
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose). rrectne
♦ The arrows on the coolant pipes and on the ends of the hoses
ss
must be aligned with each other.

o
cial p
f inform
mer
atio
3.3 Instructions for working on fuel system

om
n
c
i
or
n thi
To prevent the high-pressure fuel pump from running while it is

te
sd
a
empty and to ensure that the engine starts quickly after parts have
iv
o
pr
been renewed, it is important to observe the following:

um
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fo
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t.
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♦ If fuel system components between fuel tank and fuel high-
Co
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pressure pump are removed or renewed, initial fuel filling must
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be carried out. py by
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♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐ Prote AG.
sure pump) or fuel filter is removed or renewed
♦ Fuel system must be bled before starting engine for first time.
♦ If the high-pressure fuel pump is removed or renewed, the fuel
system must be bled before engine is started for the first time.
♦ Initial fuel filling procedure ⇒ Vehicle diagnostic tester.
• Clean tools and workbench etc. before working on injection
system.
• Thoroughly clean all joints and surrounding areas before dis‐
mantling.
• When removing components, plug all open connections im‐
mediately with suitable, clean sealing caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Place removed components in new
sealable plastic bags (if available, use original packaging of
new components).
• Before installation, check injectors and their surroundings vis‐
ually; they must be undamaged and free of lint. Ensure that
the injector bore is clean.

• Only cleaning set - VAS 6811- may be used for cleaning the
sealing surface of the injector bore.
• For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the olkswagen AG
en AG. V
⇒ operating manual provided with the cleaning setsw-agVAS does
6811- . by Volk not
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a d ran
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• If high-pressure lines are not renewed, tthey ho
ri must be labelled tee
or
on removal. High-pressure fuel lines smusts au
always be re-instal‐ ac
led in their original positions (i.e. on the same cylinder).
ce
e
nl
pt
du
an
• The following components and seals/O-rings must always be
itte
y li
renewed when the injectors are removed and installed: “cop‐
erm
ab
per seal”, “O-ring for injector bore”, “O-ring for injector return
ility
ot p
connection”, “injector return connection clip”
wit
, is n
h re
• The following components and seals/O-rings must always be
hole
spec
renewed when an injector is renewed: “copper seal”, “O-ring
es, in part or in w
for injector shaft” and “O-ring for injector return connection”
t to the co
“injector return clip”
• Always fit new copper seals for the injectors. Check all new O-
rrectness of i
rings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil). Use assembly tool
l purpos
to install the “O-ring for injector return connection”.

• Take care not to damage the injectors when removing the old
nform
ercia
copper seals.
m
at
om
• Align high-pressure lines free from tension. First tighten all
ion
c
unions hand-tight and then tighten to torque.
in t
or
his
ate
• Never attempt to reshape high-pressure fuel lines.
do
priv
cum
or
• When working on any parts of the high-pressure fuel system,

f
en
ng
t.
yi
tools may only be used for loosening and tightening pipe un‐
Co
op py
ions. All other components must always be removed and t. C rig
gh ht
installed by hand without using tools or other equipment. yri
p by
co Vo
by lksw
cted
• Disassembling individual common rail components is not per‐
agen
Prote AG.
mitted.
• The components should be replaced as complete units if faul‐
ty.
• Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
• Do not carry out any installation work on common rail system
whilst engine is running.
• In particular, do not open or release high-pressure lines and
electrical connectors.
• All cable ties which were opened or cut open during removal
must be replaced with new ties in same position during instal‐
lation.
• When the fuel system is open: do not work with compressed
air if this can be avoided. Try not to move the vehicle.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
– Clean sealing surface of injector in cylinder head and injector
shaft.
3.4 Rules for cleanliness when working on

fuel supply system
When working on the fuel supply/injection system, carefully follow
the “6 rules” below:
3. Repair notes 9
♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only. . Volkswage n AG n AG d
wage oes
♦ If the repair is not performed immediately,
Vol
ks carefully cover or not
gu
seal opened components. d by ara
ise r nte
ho eo
♦ Install only clean parts; do
sa
unot
t
remove new parts from pack‐ ra
c
aging until immediately before installing. Do not use parts that
s
ce
le
have been kept unpackaged (for example in toolboxes or sim‐

un
pt
an
d
ilar).
itte
y li
rm
ab
♦ If system is open: do not use compressed air if possible. Try
pe
ility
not to move the vehicle.
ot
wit
, is n
h re
♦ Also ensure that no diesel fuel comes into contact with the
hole
spec
es, in part or in w
t to the co
3.5 Rules for cleanliness during work on fuel
system
rrectness of i
l purpos
When working on the charge air system, pay careful attention to

the following rules for cleanliness:
nform
ercia

mantling.
m
a
com
tio
n in
r
te o
Use lint-free cloths only.
thi
s
iva
do
♦ If the repair is not performed immediately, carefully cover or
r
rp
seal opened components. cum

fo
en
ng
t.
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♦ Install only clean parts; do not remove new parts from pack‐ Cop py
. rig
t
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yri by
have been kept unpackaged (for example in toolboxes or sim‐ cop Vo
by lksw
ilar).
cted agen
Prote AG.
♦ Existing transport and protective packaging and sealing caps

must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
♦ When installing, does not use any fluid containing oil, silicone
or grease.
3.6 Rules for cleanliness when working on

injection system
When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
mantling.
Use lint-free cloths only.
♦ If the repair is not performed immediately, carefully cover or
seal opened components.
♦ Install only clean parts; do not remove new parts from pack‐
have been kept unpackaged (for example in toolboxes or sim‐
ilar).


♦ Also ensure that no diesel fuel comes into contact with the
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Repair notes 11
10 – Removing and installing engine

1 Removing and installing engine.
⇒ “1.1 Removing engine”, page 12
⇒ “1.2 Securing engine on engine and gearbox support”,
page 25
⇒ “1.3 Installing engine”, page 27
⇒ “1.4 Modifying engine bracket T10229 ”, page 29
⇒ “1.5 Converting adapter 10 - 222 A /23 with adapter 10 - 222
A /23-1 ”, page 30
1.1 Removing engine

AG. Volkswagen AG d
agen oes
olksw not
V gu
Special tools and workshop d by ara
equipment required rise nte
tho eo
au ra
♦ Hose clamps to 25 mm - ss c
ce
le
3094-
un
pt
an
d
itte
♦ Torque wrench - V.A.G
y li
erm
ab
1331-
ility
ot p
wit
is n
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1332-
ole,
spec
♦ Engine and gearbox jack -
t to the co
V.A.G 1383 A-
♦ Ratchet attachment - V.A.G
1410/3-
rrectne
♦ Step ladder - VAS 5085-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
12 Rep. gr.10 - Removing and installing engine

♦ Workshop hoist - VAS

6100-
♦ Set of plugs for engine -
VAS 6122-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clamp pliers - VAS
6340-
♦ Spring-type clip pliers -
VAS 6362-
♦ Engine bracket - T10229 A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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un
pt
an
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itte
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rm
ab
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ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Threaded stud - T10229 A/1-

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Removing and installing engine. 13

♦ adapters - T10261-
♦ High-temperature grease ⇒ Electronic parts catalogue (ET‐

KA)
♦ Cable tie
Sequence of operations
swage es n
If necessary, modify engine support - T10229- ⇒ page by V 29 .
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
Note ss
ce
le
un
pt
♦ Before carrying out further work, remove the battery. There‐
an
d
itte
y li
fore, first check whether a coded radio is fitted. Obtain anti-
erm
ab
theft coding beforehand if necessary.
ility
ot p
wit
is n
♦ The engine is removed downwards together with the gearbox
h re
ole,
and engine wiring harness.
spec
♦ All cable ties that are opened or cut through when the engine
t to the co
is removed must be renewed/replaced in the same position
when the engine is installed.
rrectne
♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
s
♦ Collect drained coolant into a clean container for re-use or
s o
cial p
disposal. f inform
mer
atio
m
Caution
o
n
c
i
or
n thi
te
sd
a

iv
o
pr

cum
r
fo
itations:
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
c by lksw
cted agen
is re-established.
Prote AG.
♦ To avoid damaging lines, make sure there is sufficient

clearance to all moving or hot components.

– Undo nuts -2-.

– Remove wiring harness -1-.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Only detach front left bumper cover ⇒ General body repairs,
exterior; Rep. gr. 63 ; Front bumper; Removing and installing
front bumper cover .
– Remove left headlight ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
– Remove upper part of electronics box ⇒ Electrical system;
Rep. gr. 97 ; Relay carrier, fuse carrier, electronics boxes;
Removing and installing electronics boxes .
– Disconnect connector -4-.

– Open clip -1-.
– Unplug electrical connectors -2, 3, 5, 6-.
– Remove wiring harness with seal -7- from electronics box and
place to one side.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew nuts -1- and -4-.

wit
, is n
h re
– Remove wiring harness -2- and -3-.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove wiring harness with seal -1- from electronics box and
place to one side.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Drain coolant ⇒ page 187 .
– Remove subframe without steering rack ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐
ling subframe without steering rack .
– Remove right and left drive shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Remove particulate filter ⇒ page 474 .
– Unscrew bolt -1- from support mounting -3-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unscrew bolts -2- and bolt -3- and remove rear torque reaction
t to the co
support -1-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew nut -5- and remove coolant circulation pump 2 -

V178- -1-.
– Unscrew bolts -1- and bolt -4- from front torque reaction sup‐
port -3-.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
rise nte
– Unscrew bolts -4- from subframe utho -3- or bolt -2- and remove eo
ra
front torque reaction supportss-1-.
a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
If bolt -2- has been loosened, tighten this bolt last as it also carries
wit
, is n
out a vertical tolerance compensation.

h re
hole
spec
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– Unscrew bolt -2- from pressure pipe -1-.

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The bolts -2- need only to be loosened. They are unscrewed later.
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The screw-type clip -2- is secured in the pressure hose -1- with
“barbs”. Only the bolt has to be released.
– Open screw type clip -2- and pull hose off -1-.
– Open screw-type clip -2- and remove hose -1-.

– Pull off hose -1-.
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– Separate connector -1-.

– Move electrical wiring harness -4- clear.
– Unscrew bolts -3-.
– Move coolant expansion tank -2- aside slightly with coolant
hoses still attached.
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– Open clamps -1- and -4-. Remove fuel supply line -3- and fuel
om
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– Pull vacuum hose -2- off vacuum pump -1-.
– Open clamps -1- and -2-. Pull off coolant hoses -3- and -4-.
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Vehicles with an air conditioner:
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Note
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ses, ensure that lines and hoses are not stretched, kinked or bent.
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– Secure air conditioner compressor to body so that refrigerant

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– Screw off vane pump for power-assisted steering together with cted agen
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connected lines and fasten to body ⇒ Running gear, axles,
steering; Rep. gr. 48
Vehicles with dual clutch gearbox:
– Remove selector lever cable from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector lever
cable .

– Clamp off coolant hoses -1- and -2- using hose clamps to 25
mm - 3094- and disconnect hoses from gear oil cooler.
– Route coolant hoses -1- upwards and tie-up.
– Release quick-release cover by turning it -arrow- and then pull

it off.
Vehicles with manual gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Detach gear selector cable.
– Pull out clip -arrow- and disconnect line from connector of hy‐
draulic clutch slave cylinder.
– Seal line at slave cylinder with clean plugs from engine bung
set - VAS 6122- . en AG. V
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– Remove bevel box ⇒ Rep.
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– Secure stud - T10229 A/1- -1- with recess -arrow- on engine

so that bolt -2- can be removed.
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– Screw stud - T10229 A/1- -2- with nut and washer firmly into
hole -1- in cylinder block with approximately 20 Nm.
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– Attach engine bracket - T10229 A- with support pin in hole
-arrow- in cylinder block. Tighten studs - T10229 A/1- on en‐
rrectness of i
gine support to 50 Nm.
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The two studs must be secured to the engine support - T10229

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– Bring engine support - T10229 A- to zero-degree position for

removal by turning adjuster screw -1-.
– Insert engine bracket - T10229 A- with support pin -2- into en‐
gine and gearbox jack - V.A.G 1383 A- and raise engine/
gearbox unit slightly.
Note
Use stepladder - VAS 5085- to unscrew bolts.

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hoses are damaged.
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Note
When lowering the engine with gearbox, guide them carefully to

avoid damage.
– Check needle bearing -arrow- in crankshaft. If it is damaged

or has turned blue, it must be renewed ⇒ page 75 .
– If it is not damaged, grease it lightly with high-temperature
grease as per ⇒ Electronic Parts Catalogue (ETKA) .
– End of gearbox shaft (but not splines) also must be lightly
greased.
1.2 Securing engine on engine and gearbox

support
Special tools and workshop equipment required

♦ Lifting tackle - 3033-
♦ Engine and gearbox support - VAS 6095A-
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♦ Workshop hoistor - VAS 6100-
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♦ Engine and gearbox jack - VAS 6931-

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• Engine removed
• Engine with engine support - T10229 A- secured on engine
and gearbox jack - VAS 6931-
– Push engine and gearbox jack - VAS 6931- to a workbench.

– Lower engine and gearbox until gearbox comes to rest on

workbench.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
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– Remove bolts -1 … 8-.
– Unbolt gearbox.
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Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 3rd hole in hook rail at position 8
– Secure engine on engine and gearbox support - VAS 6095 A- .
1.3 Installing engine


♦ Vehicle diagnostic tester

Installing
Install in the reverse order of removal, observing the following:
Note
If installing a base engine, make absolutely sure that the bolts of

the clamping pieces ⇒ Item 18 (page 375) are not tightened until
after the high-pressure lines are fitted.
– Check clutch release bearing for wear and, if necessary, re‐

place (gearbox removed).
– Lightly grease input shaft splines with grease ⇒ Electronic
Part Catalogue (ETKA) (gearbox separated).
– Check whether dowel sleeves for centring engine/gearbox are
in cylinder block and install if necessary (gearbox removed).
– Fit and tighten screw-type clips with “barbs” ⇒ page 347 .
– Install engine with engine support - T10229 A- in zero-degree
position.
– Tighten new bolts -2-.
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– Tighten new bolts -arrows A- to body.
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– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

itte
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40 ; Drive shaft; Removing and installing drive shaft .

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Vehicles with manual gearbox:

hole
spec
– Join connector of line to hydraulic clutch slave cylinder ⇒ Rep.

es, in part or in w
t to the co
gr. 30 ; Clutch operation; Removing and installing clutch slave

cylinder .
– Install selector mechanism ⇒ Rep. gr. 34 ; Selector mecha‐
rrectness of i
nism; Removing and installing selector mechanism .

l purpos
– Install gear selector cable.

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– Attach and adjust selector lever cable of gearbox ⇒ Rep. gr.

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34 ; Selector mechanism; Checking and adjusting selector

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Rep. gr.10 - Removing and installing engine Prote AG.
– When loosening or tightening threaded connection, pressure

line for power-assisted steering must be unbolted from sub‐
frame. Pressure line must not be raised by more than dimen‐
sion -a- = 5 mm in this case.
– Position and screw adapter - T10261- onto rear torque reac‐
tion support bolt using ratchet - V.A.G 1410/3- .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install front torque reaction support ⇒ page 34 .
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank and
the high-pressure pump are removed or renewed, it is neces‐
sary for the fuel system to be bled. To do this, perform the
Bleeding fuel system function using ⇒ Vehicle diagnostic
tester Guided Functions .
♦ This process takes 130 seconds. Fuel pumps are actuated sawagen AG. Volkswagen AG does
total of 3 times in the process. The process must not be y Vter‐
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– If present, attach noise insulation ⇒ General body
au repairs, ac
ss
exterior; Rep. gr. 66 ; Noise insulation; Removing and instal‐
ce
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ling noise insulation .
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– Add coolant ⇒ page 187 .
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Torque settings
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♦ ⇒ “2.3 Removing and installing motor mounting”, page 34
♦ ⇒ “2.1 Assembly overview - particulate filter”, page 467
rrectness of i
♦ Noise insulation; Exploded view - noise insulation ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded
l purpos
view - noise insulation

♦ Lock carrier; Assembly overview - lock carrier ⇒ General body
nf
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repairs, exterior; Rep. gr. 50 ; Lock carrier; Assembly overview
rm
m
- lock carrier
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♦ Front bumper; Assembly overview - front bumper ⇒ General

or
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body repairs, exterior; Rep. gr. 63 ; Front bumper; Assembly

t
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overview - bumper cover

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♦ Air conditioner compressor; Removing and installing air con‐

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ditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Cop py
Air conditioner compressor ht. rig
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♦ Subframe; Assembly overview - subframe ⇒ Running gear,
by lksw
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axles, steering; Rep. gr. 40 ; Subframe; Assembly overview -
AG.
subframe
♦ Headlights; Assembly overview - headlights ⇒ Electrical sys‐
tem; Rep. gr. 94 ; Headlights; Assembly overview - headlights
Component Torque setting
Bolts for coolant expansion 3.5 Nm
tank
1.4 Modifying engine bracket - T10229-


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♦ Straight edge
♦ Hand drill
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Note
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♦ Engine support - T10229- must only be modified if no engine

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♦ Stud - T10229 A/1- is required to separate engine and gearbox

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T10229 A/1
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– Drill another hole in engine support - T10229- as shown in

illustration.
– Add a permanently legible “A” to the number “T10229”.
1.5 Converting adapter - 10 - 222 A /23- with

adapter - 10 - 222 A /23-1-
♦ Torque wrench - V.A.G 1331-

♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-
– Remove cap -1-.
– Remove cap -2- and unscrew underlying support bolt -3-.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Insert bolt -6- into adapter - 10 - 222 A /23- from below and
tighten to 40 Nm.
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2 Assembly mounting
⇒ “2.1 Assembly overview - assembly mountings”, page 32
⇒ “2.2 Supporting engine in installation position”, page 33
⇒ “2.3 Removing and installing motor mounting”, page 34
⇒ “2.4 Removing and installing engine mounting”, page 38
2.1 Assembly overview - assembly mountings
1 - engine mounts
❑ right
❑ Removing and installing
⇒ page 35
2 - Bolt
❑ Renew after removal
❑ 90 Nm +90°
3 - Bolt
❑ 50 Nm +90°
4 - Bolt agen
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⇒ page 35
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7 - Bolt
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❑ 50 Nm +90°
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8 - Engine support
❑ Rear ⇒ page 36
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9 - Bolt
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11 - Motor mounting
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❑ Rear ⇒ page 37
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12 - Bolt
❑ 50 Nm +90°
13 - Bolt

❑ 90 Nm +180°
14 - Motor mounting
❑ Front ⇒ page 37
15 - Engine support
❑ Front ⇒ page 37
16 - Bolt
❑ 50 Nm +90°
17 - Motor mounting
❑ right
❑ Removing and installing ⇒ page 34
2.2 Supporting engine in installation position
Special tools and workshop

equipment required
♦ Support - 10 - 222 A-
♦ adapters - 10 - 222 A /3-
♦ adapters - 10 - 222 A /16-
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♦ Adapter - 10 - 222 A /23- ksw
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– Remove plenum chamber bulkhead on left and right ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Plenum chamber
2. Assembly mounting 33
bulkhead; Removing and installing plenum chamber bulk‐

head .
– If necessary, equip adapter - 10 - 222 A /23- with adapter - 10
- 222 A /23-1- .
– Remove cap -1-.
– Remove cap -2-, and unscrew support bolt -3- located beneath
it.
– Insert adapter - 10 - 222 A /23-1- -4- into adapter - 10 - 222
A /23- -5-.
– Insert bolt -6- into adapter - 10 - 222 A /23- from below and
tighten to 40 Nm.
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– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /23-

and adapter - 10 - 222 A /23-1- as shown and take up weight h re
hole
of engine in installation position. spec

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2.3 Removing and installing motor mounting

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– Remove air filter housing ⇒ page 432 .

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– Support engine in its installation position ⇒ page 33 . t. Cop py
rig
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cted agen
Prote AG.
The mountings for the power unit mounting must be tightened in

the following order!

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2010 ➤ , Multivan 2010 ➤ , Transporter 20or... ac
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4-cylinder diesel sengine (2.0 l engine, common rail) - Edition 08.2016
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• 1. Gearbox mounting
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• 2. Engine mounting
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• 3. Connection of rear support mounting to rear torque reaction
h re
support ⇒ page 36
hole
spec
es, in part or in w
• 4. Connection of front support mounting to front torque reac‐
t to the co
tion support ⇒ page 37
Fastening the engine bearing to longitudinal member
rrectness of i
– Securely attach engine mounting -2- to longitudinal member
l purpos
-3- using bolts -1-.
Torque setting
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Engine mounting bolt 50 Nm +90°
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Engine carrier to engine mounting and engine support
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Torque setting
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Component Torque setting Prote AG.
Engine carrier bolt to engine 90 Nm +90°

mounting -1-
Engine carrier bolt to engine 50 Nm +90°
support -2-
Engine support to engine

– Tighten bolts in sequence -1- to -3-.
Torque setting
Engine support bolt 40 Nm +180°
Rear torque reaction support

– Bolt rear torque reaction support -1- to engine -4- using bolts
-2- and bolt -3-.
Torque setting
Bolt -2- 50 Nm +90° AG. Volkswagen AG d
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Bolt -3- 20 Nm +90°y Volksw not
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Rear torque reaction support to support mounting
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♦ Bolt -1- is the penultimate to be tightened for all operations as
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t to the co
♦ Bolt -1- must always be renewed.
rrectness of i
– Bolt rear torque reaction support -2- to support mounting -3-
using bolt -1-.
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– When loosening or tightening threaded connection, pressure t. Cop py
line for power-assisted steering must be unbolted from sub‐
rig
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frame. Pressure line must not be raised by more than dimen‐ cop Vo
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Prote AG.
Torque setting
Torque reaction support to sup‐ 50 Nm +90°
port mounting

Support mounting to assembly carrier

– Securely fasten support mounting -2- to subframe -3- using
bolts -1- and nuts -4--
Torque setting
Bolts -1- and nuts -4- for sup‐ 20 Nm +180°
port mounting AG. Volkswagen AG d
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Front torque reaction support
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Note
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♦ Bolt -2- is the last to be tightened for all work, as this is used
to achieve vertical tolerance compensation.
nform
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♦ Always renew bolts.

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– Bolt front torque reaction support -1- to mounting -3- using bolt
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-2-.
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Torque setting
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Component Torque setting ht. Cop py
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Bolt -2- for front torque reaction 90 Nm +180°
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support
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Front engine mounting to subframe

– Bolt front torque reaction support -1- to subframe -3- using bolt
-4-.
– If necessary, remove bolt -2- to facilitate further assembly.
Torque setting
Bolts -4-. 20 Nm +90°
Front engine support to engine

– Bolt front torque reaction support -3- to engine -2- using bolts
-1- and bolt -4-.
Torque setting
Bolts -1 and 4- agen 50 Nm +90° AG does
AG. Volkswagen
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Gearbox mounting
– Bolt gearbox mounting to longitudinal member using bolts
rrectness of i
-A-.
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– Bolt gearbox mounting to gearbox using bolts -B-.
nf
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Note
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c
Always renew bolts.

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Torque setting
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Cop py
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Bolts -arrows- 50 Nm +90°
rig ht
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co Vo
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Prote AG.
Vibration damper
– Remove cap -2-.
– Unscrew bolt -3-.
– Remove damper weight -1-.
Torque setting
Bolt -3- 20 Nm
2.4 Removing and installing engine mount‐

ing
Removing
– Remove air filter housing ⇒ page 432 .
– Support engine in its installation position ⇒ page 33 .


– Lift retaining clip (not visible in picture) and pull pressure hose
-1- off charge air cooler -arrow-.

Notes on hose connections with screw-type clamps
⇒ page 347
Caution
AG. Volkswagen AG d
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• Do not loosen the screw-type clipd b-1-
y V and pull back over
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the pressure hose. Risk of damage
orise to the pressure hose! nte
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pt
du
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ab
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spec
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t to the co
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pressure hose.
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Vehicles with “bi-turbo engine”

nform
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– Detach connecting hose on pulsation damper and lay aside.

m
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Continuation all vehicles

ion
c
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or
– Remove plenum chamber bulkhead on left and right ⇒ Gen‐

his
ate
eral body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing

do
priv
and installing bulkhead .

cum
for
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op
C py
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noise insulation .
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pyri by
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Prote AG.
Note
The engine mounting may only be removed if the engine is sup‐

ported with support bracket - 10 - 222 A- !
– Unscrew bolt -1- from engine mounting -5-.
– Unscrew bolts -2- of engine carrier -4- out of engine support

-3-.
– Remove nut -2- and holder -1- for power-assisted steering

pressure line.
– Unscrew bolts of engine support in sequence -3…1-.

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– Remove engine support. ed by ara
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Installing utho eo
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Install in reverse order of removal, observing the following:
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Caution
erm
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ility
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The tightening sequence and specified torques for the engine

, is n
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support bolts must always be followed. Otherwise the engine

hole
spec
support can be stressed and it can break.

es, in part or in w
t to the co
– Insert engine support.

rrectness of i
– Tighten new bolts.

l purpos
– Use the spindle to bring the engine support to rest on the en‐
gine mounting.
nf
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Torque settings
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♦ Noise insulation; Assembly overview – noise insulation ⇒

thi
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General body repairs, exterior; Rep. gr. 66 ; Noise insulation;

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Assembly overview – noise insulation

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♦ Plenum chamber bulkhead; Assembly overview - plenum

t.
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chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. C py
t. rig
50 ; Bulkhead; Assembly overview - plenum chamber cover
gh ht
pyri by
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cted agen
Prote AG.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”,
page 41
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
43
⇒ “1.3 Assembly overview - poly V-belt drive”, page 45
⇒ “1.4 Removing and installing poly-V belt”, page 49
⇒ “1.5 Removing and installing tensioner for poly V-belt”,
page 51
⇒ “1.6 Removing and installing ancillary bracket”, page 52
⇒ “1.7 Removing and installing vibration damper”, page 54
⇒ “1.8 Renewing crankshaft oil seal - belt pulley end”,
page 55
⇒ “1.9 Removing and installing sealing flange on pulley end”,
page 57
1.1 Assembly overview - cylinder block (pul‐

ley end)
Note
If large quantities of metal filings or abraded matter are found in

the engine oil during engine repairs, the oil ductsGmust be cleaned
n A . Volkswagen AG do
carefully. It is also essential to renew thelkengine
swage oil cooler. Failure es n
to do so can result in damage. by
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Cop py
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Prote AG.
1. Cylinder block (pulley end) 41

1 - Cylinder block
2 - Guide tube
❑ Renew O-ring after
each removal
3 - Fastener
4 - Seals
❑ May not be lubricated
with oil
❑ Fit into lugs on oil filter
bracket.
5 - Oil filter bracket
❑ Fitted in only vehicles
with “single turbo en‐
gine”.
6 - Bolt
❑ 14 Nm +180°
❑ Tighten bolts diagonally
and alternately
7 - Bolt
❑ 13 Nm
8 - Ball thermostat (4/2-way agen
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❑ Removing and installing s
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⇒ page 228
un
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9 - O-ring
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10 - Lifting eye h re
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spec
11 - Ancillary bracket
es, in part or in w
t to the co

12 - Bolt
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❑ Observe different prescribed torques and tightening sequence ⇒ page 52

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13 - Bolt
❑ 25 Nm
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14 - Oil pan
m
❑ Clean sealing surface before fitting.

com
tion in
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .

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15 - Bolt
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❑ 15 Nm
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42 Rep. gr.13 - Crankshaft group

Check coolant holes

– Check coolant holes -1- for blockage with a thin wire -2-.
– Carefully remove any blockages found so that they do not get
into the coolant again.
AG. Volkswagen AG d
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1.2 Assembly overview - sealing flange, belt pulley end
rrectness
1 - Bolt
o
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f in
form
mer
❑ Loosen and tighten with

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counterhold - 3415-
o
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❑ Do not additionally oil

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the thread and shoulder.

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❑ 180 Nm + 135°
r
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ng
t.
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2 - Crankshaft pulley . Cop py
rig
ht
❑ The contact surface be‐ rig ht
py by
tween toothed belt pul‐
co Vo
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ley and crankshaft must
agen
Prote AG.
be free of oil.
❑ Can only be fitted in one
position
3 - Crankshaft oil seal for belt
pulley end
❑ Do not apply additional
oil or grease the sealing
lip of the oil seal.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 55
4 - Sealing flange at belt pulley
end
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Must seat on dowel
pins.
⇒ page 57

5 - Cylinder block
6 - Dowel pin
❑ Qty. 2
7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 44
Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts for sealing flange at belt pulley end in the se‐
quence -1 … 10- in 3 stages as follows:
1. Screw in bolts -1 … 10- by hand until heads make contact.
2. Tighten bolts -1 … 6- in diagonal sequence to 15 Nm. AG. Volkswagen
n AG do
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3. Tighten bolts -7 … 10- to 15 Nm. Volks ot g
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Cop py
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1.3 Assembly overview - poly V-belt drive n AG. Volkswagen AG do

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⇒ “1.3.1 Assembly overview - poly-V-belt drive for vehicles d by with
Vo ot g
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air conditioning system”, page 45 o
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⇒ “1.3.2 Assembly overview - poly-V belt drive on vehicles
ss
a without ac
A/C system”, page 47
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1.3.1 Assembly overview - poly-V-belt drive for vehicles with air conditioning sys‐
itte
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ab
tem
ility
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1 - Poly V-belt
spec
es, in part or in w
❑ Mark direction of rota‐
t to the co
tion before removing
❑ Check for wear
rrectness of i
❑ Do not kink.
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⇒ page 49
nf
ercia
2 - Bolt
orm
m
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❑ 10 Nm +90°
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3 - Belt pulley and vibration

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damper
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❑ Installation position:
f
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t.
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hole in vibration damper
Co
op py
must align over protru‐
t. C rig
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sion on crankshaft pul‐ p by
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ley.
by lksw
cted agen
Prote AG.
❑ Can be installed only in
one position - bores are
offset
⇒ page 54
4 - Bolt
❑ 20 Nm
5 - Idler roller
❑ For toothed belt
6 - Dowel sleeve
❑ Check for correct seat‐
ing in ancillary bracket.
❑ Inserted in hole for left
(in direction of travel)
bolt -11- on rear side of
bracket.
7 - Ancillary bracket
❑ Observe prescribed torque and tightening sequence during installation ⇒ page 47
8 - High-pressure pump
9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
10 - Bolt
❑ The bolt can be reused. The torque setting must be adjusted to 20 Nm +90°.
❑ New bolt: 20 Nm + 180°

AG. Volkswagen AG d
agen oes
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California 2010 ➤ , Caravelle 2010 ➤ , Multivan by V 2010 ➤ , Transporter 20 ... ot gu
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ara
d
4-cylinder diesel engine (2.0 l engine, common
oris
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11 - Double stud s
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❑ 40 Nm +90°
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12 - Bolt
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spec
❑ 40 Nm +90°
es, in part or in w
t to the co
13 - Bolt
❑ 25 Nm
rrectness of i
14 - Sleeve
❑ Before installing, drive back vane pump slightly
l purpos
15 - Holder
nf
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16 - Nut
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❑ 25 Nm
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17 - Bolt
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❑ 40 Nm +180°
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18 - Vane pump t. Cop py
rig
gh
❑ Removing and installing ⇒ Rep. gr. 48 ; Hydraulic power steering; Removing and installing vane pump
ht
pyri by
Vo
co lksw
by
19 - Bolt
cted agen
Prote AG.
❑ 25 Nm
20 - Belt pulley
21 - Bolt
❑ 25 Nm
22 - Bolt
❑ 23 Nm
23 - Bolt
❑ 20 Nm +90°
24 - Idler roller
❑ Remove and install using wrench for door adjustment - 3320- or socket wrench XZN 10 - T10154- and
appropriate socket
25 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 .
26 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
27 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken poly V-belt ⇒ page 49
28 - Bolt
❑ 20 Nm +45°

Ancillary bracket - specified torques and tightening sequence

– Insert bolts for ancillary bracket as follows:
♦ Bolts -1- and -2-
– Tighten bolts for ancillary bracket in sequence -1 … 6- in 2
stages as follows:
1. Screw all bolts in to stop by hand.
2. Tighten all bolts to 40 Nm.
3. Turn bolts -1, 2, 5 and 6- 90° further.
4. Turn bolts -3- and -4- 180° further.
1.3.2 Assembly overview - poly-V belt drive on vehicles without A/C system
1 - Poly V-belt
❑ Check for wear
❑ Do not kink.
⇒ page 49
2 - Bolt
❑ 10 Nm +90° lkswage es n
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3 - Belt pulley and vibration ir se
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damper auth or
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❑ Installation position: ss
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must align over protru‐

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sion on crankshaft pul‐

erm
ab
ley.
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❑ Can be installed only in

h re
one position - bores are

hole
spec
offset
es, in part or in w
t to the co

⇒ page 54
4 - Bolt
rrectness of i

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❑ 20 Nm +45°
5 - Idler roller
nf
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❑ For toothed belt

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6 - Dowel sleeve
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❑ Check for correct seat‐

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ing in ancillary bracket.

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❑ Inserted in hole for left

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(in direction of travel)

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bolt -11- on rear side of bracket.
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California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 yV
➤
o , Transporter 20 ...
lks ot g
b ua
ir se - Edition 08.2016
d ran
tee
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7 - Ancillary bracket ss
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le
❑ Observe prescribed torque and tightening sequence during installation ⇒ page 47
un
pt
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ility
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9 - Alternator
h re
hole
spec
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
es, in part or in w
t to the co
10 - Bolt
❑ The bolt can be reused. The torque setting must be adjusted to 20 Nm + 90°.
❑ New bolt: 20 Nm + 180°
rrectness of i
11 - Double stud l purpos
nform
ercia
❑ 40 Nm +90°
m
12 - Bolt
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tion in
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❑ 40 Nm +90°
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13 - Bolt
um
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❑ 25 Nm
t.
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Cop py
. rig
14 - Sleeve
t
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pyri by
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❑ Before installing, drive back vane pump slightly
c by lksw
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Prote AG.
15 - Holder
16 - Nut
❑ 25 Nm
17 - Bolt
❑ 40 Nm +180°
18 - Vane pump
❑ Removing and installing ⇒ Rep. gr. 48 ; Hydraulic power steering; Removing and installing vane pump
19 - Bolt
❑ 25 Nm
20 - Belt pulley
21 - Bolt
❑ 25 Nm
22 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
23 - Poly V-belt tensioning element
❑ Swing with ring spanner to slacken poly V-belt ⇒ page 49

Ancillary bracket - specified torques and tightening sequence

– Insert bolts for ancillary bracket as follows:
♦ Bolts -3- and -4- lkswage es n
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♦ Bolts -5- and -6- o
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– Tighten bolts for ancillary bracket
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stages as follows:
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1. Screw all bolts in to stop by hand.
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2. Tighten all bolts to 40 Nm.
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3. Turn bolts -1, 2, 5 and 6- 90° further.
h re
hole
spec
4. Turn bolts -3- and -4- 180° further.
es, in part or in w
t to the co
rrectness of i
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1.4 Removing and installing poly-V belt

nform
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♦ Pin - T10060 A-
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Removing
noise insulation .
– Mark running direction of poly V-belt.
– Turn the tensioning element -1- in -direction of arrow- with ring
spanner SW 16 -2- to slacken the poly-V belt.

– Use the locking pin - T10060 A- to lock the tensioning element

in place.
– Remove poly V-belt.
Installing
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor, power-assisted steering
vane pump) are secured tightly.
♦ When fitting the poly V-belt observe belt direction of rotation
and that the belt is seated correctly in the belt pulleys.
♦ Place the poly-V belt last on the tensioning element.
– Remove locking pin - T10060 A- .

After completing repair, always:
– Start engine and check belt running.
Belt drive without air conditioner compressor

1- Tensioning pulley
2- Alternator pulley
3- Vane pump
4- Poly V-belt
5- Crankshaft pulley
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Belt drive with air conditioner compressor

1- Crankshaft pulley AG. Volkswagen AG d
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1.5 Removing and installing tensioner for
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Removing
noise insulation .
– Remove poly V-belt ⇒ page 49 .
– Remove front torque reaction support ⇒ page 37 .
– Loosen air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87
Note
♦ Do not release any refrigerant lines from air conditioner com‐

pressor.
♦ Secure air conditioner compressor to body so that refrigerant
♦ Refrigerant circuit remains closed.

– Remove tensioning element for poly V-belt -1-.

Installing
♦ Install poly V-belt ⇒ page 49 .
♦ Install front torque reaction support ⇒ page 34 .
♦ If present, install noise insulation ⇒ General body repairs, ex‐
noise insulation
Torque settings
♦ ⇒ “1.3 Assembly overview - poly V-belt drive”, page 45
ditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor
1.6 Removing and installing ancillary brack‐

et
Special tools and workshop oequipment
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♦ Adapter - 10 - 222 A /23- with adapter - 10 - 222 A /23-1-

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Removing
– Remove engine support ⇒ page 38 .
– Remove high-pressure pump ⇒ page 454 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .

WARNING
The air conditioner refrigerant circuit must not be opened.
– Secure air conditioner compressor to body so that refrigerant

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87
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– Screw off vane pump for power-assisted steering kstogether
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– Unbolt idler rollers -1- and -2- and sunscrew
sa bolt from toothed c
belt guard -arrow-.
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– Withdraw wiring harness -1- from bracket -2-.
nform
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Note
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A small hand-held mirror is required to unscrew and insert nut
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WARNING
rrectness of i
Ancillary bracket - observe specified torques and tightening
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sequence ⇒ page 47
nform
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– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;

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Removing and installing alternator .
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♦ ⇒ “2.1 Assembly overview - toothed belt”, page 120
ditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor
♦ Alternator; Assembly overview - alternator ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Alternator; Assembly overview - alternator .
1.7 Removing and installing vibration damp‐

er

Removing
– Unscrew bolts -1- while counterholding on centre bolt.
– Remove vibration damper -2-.
Installing
• Installation position: hole -arrow- in vibration damper must
align over protrusion on crankshaft pulley.
Torque settings
1.8 Renewing crankshaft oil seal - belt pulley end
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equipment required
♦ Seal puller - 3203-
♦ Retainer - 3415-
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Removing
– Remove toothed belt ⇒ page 122 .
– Using counterhold tool - 3415- , loosen bolt -1- for crankshaft
pulley -2-.
– Remove crankshaft pulley -2-.

– To guide seal extractor - 3203- , screw centre bolt into crank‐

shaft as far as stop by hand.
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
from the outer part and lock in position with the knurled screw.
– Oil threaded head of seal extractor.
– Screw oil seal extractor forcibly as far as possible into oil seal.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.

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– Install and tension toothed belt ⇒ page 122 .

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Torque settings
spec
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♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,

page 43
rrectness of i
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1.9 Removing and installing sealing flange

nform
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on pulley end
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♦ Assembly tool - T10053-
Removing
– Using counterhold tool - 3415- , loosen bolt -1- for crankshaft
pulley -2-.
– Remove crankshaft pulley -2-. agen
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– Remove oil pan ⇒ page 160 . byV gu
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– Unscrew bolts -1 … 10- and carefully remove sealing flange

from the glued joint.
rrectness of i
– Remove sealing flange. If necessary, loosen sealing flange

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using light blows with a rubber headed hammer.

– Remove sealant residues from cylinder block with a flat scra‐
nform
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Rep. gr.13 - Crankshaft group
– Remove sealant residue from sealing flange with a rotating

plastic brush (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Use sealant as per ⇒ Electronic Parts Catalogue (ETKA) .
Note
♦ Check the expiry date of the sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
♦ The sealant bead must be no thicker than 2 to 3 mm. Excess
sealant can find its way into the sump and block the strainer
in the suction line and drip on the sealing surface of the crank‐
shaft seal. agen
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– Install oil pan ⇒ page 160 .
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Note
ss
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– Install toothed belt and adjust the valve timing ⇒ page 122 .
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2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 61
⇒ “2.2 Removing and installing flywheel”, page 62
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 63
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt agen
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3 - Sender wheel
❑ For engine speed send‐
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er - G28-
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⇒ page 63
4 - Engine speed sender -
nform
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G28-
m
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⇒ page 506
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5 - Bolt
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❑ 5 Nm
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❑ Must seat on dowel
pins.
❑ Attach to sealing flange
⇒ page 62
8 - Sealing flange, gearbox
side
❑ With shaft seal
❑ With sender wheel for engine speed.
❑ Renew complete only.
❑ Do not apply additional oil or grease the sealing lip of the oil seal.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
9 - Bolt
❑ 15 Nm
2. Cylinder block, gearbox end 61

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Fitting cover
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– Attach cover to sealing flange -arrow at top- and push onto
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dowel pins -arrows at bottom-.
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Sealing flange on gearbox side - specified torque and tightening

sequence
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2.2 Removing and installing flywheel


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nl
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– Insert counterhold tool - 3067- into hole in cylinder block
ility
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-item B-.
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– Unscrew flywheel bolts -1-.
hole
spec
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Installing
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Note
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♦ Observe TPI 2038587 without fail!
nform
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♦ Flywheel with sender wheel can only be fitted in one position.

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– Insert counterhold - 3067- in hole in cylinder block -item A-.
n
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♦ Gearbox; Installing gearbox ⇒ Rep. gr. 34 ; Removing and
by lksw
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installing gearbox; Installing gearbox
Prote AG.
2.3 Removing and installing sealing flange on gearbox side


equipment required
1331-
♦ Tool insert 24 mm - V.A.G
1332/11-
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♦ Depth gauge - VAS 6082-

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♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm

Removing
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing

gearbox .
Pressing out sealing flange with sender wheel
– Remove dual-mass flywheel ⇒epage
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The crankshaft marking -arrow- aligns with the drawn cross.

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– Remove oil pan ⇒ page 160 .

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– Remove engine speed sender - G28- -arrow-.
AG.
– Unscrew bolts of sealing flange.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together with 3 x M6 × 35 mm bolts.

– Screw in 3 M6 x 35 mm bolts into threaded holes of sealing

flange -arrows-.
– Screw bolts (max. 180° per bolt) into sealing flange alternately
in order to press it and the sender wheel of crankshaft togeth‐
er.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with a wPTFE

agen seal is equipped
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♦ The assembly device - T10134- is held in its position relative
spec
to the crankshaft by a guide pin inserted into a hole in the
t to the co
crankshaft.
Assembly tool - T10134- rrectne

A - Clamping surface
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G - Guide pin for petrol engines (red knob)
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– Screw on nut -B- until just before it touches the clamping sur‐
AG.
face -A- of the threaded spindle.

– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on nut
-B- -arrow-.
– Screw nut onto threaded spindle until inner part of assembly
device and assembly housing are at same height.
– Remove safety clip -arrow- of the new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean
level surface.
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– Push sealing lip support ring -A- downwards in direction of ar‐

ility
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row until it lies on flat surface.

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es, in part or in w
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AG. Volkswagen AG d
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– Upper edge of sender bwheel yV
o and front edge of sealing oflange
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ara
must align -arrows-. rised
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spec
es, in part or in w
t to the co
– Place sealing flange with front side facing downwards onto
rrectness of i
assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
l purpos
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ercia
Note
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io
Ensure sealing flange lies flat on assembly tool.
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– Push sealing flange and support ring for sealing lip -B- against co Vo
by lksw
surface of assembly tool - T10134- whilst tightening the 3 cted agen
Prote AG.
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly tool.
B - Fit assembly tool - T10134- with sealing flange on crankshaft

flange
• Crankshaft flange must be free of oil and grease.
• Engine is positioned at TDC of cylinder 1
– Screw nut -B- on until it reaches end of threaded spindle.

– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing to crankcase's sealing sur‐
face on the oil sump side.

– Secure assembly tool - T10134- to crankshaft flange with hex‐

agon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange into cylinder block, screw in two M7 ×

35 mm bolts -A-.
C - Bolting assembly tool - T10134- onto crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until

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sealing lip support ring -B- touches crankshaft
kswagen Aflange -A-. oes
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– Push guide pin for diesel engines e(black
db knob) -D- into hole in ara
nte
crankshaft. This ensures that ttheoris sender wheel reaches its fi‐ eo
h
nal installation position. ss au ra
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Note
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The guide pin for petrol engines (red knob) -F- must not be inser‐
wit
is n
ted in threaded hole of crankshaft.

h re
ole,
spec
– Tighten the two hexagon socket head bolts of the assembly

t to the co
tool hand-tight.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
rrectne
D - Pressing sender wheel onto crankshaft flange using assembly

s
tool - T10134-
s o
cial p
f inform
mer
atio
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– Tighten nut of assembly tool - T10134- using torque wrench -

V.A.G 1331- and flared ring spanner tool insert AF 24 - V.A.G
1332/11- .
Note
After hexagon nut is tightened, a small air gap must still be present
between cylinder block and sealing flange.
Torque setting
Nut for assembly tool 35 Nm
E - Checking sender wheel installation position on crankshaft
– Screw nut -E- on until it reaches end of threaded spindle.

– Unscrew 2 bolts -A- from cylinder block.
– Unscrew 3 knurled screws -B- out of sealing flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
AG. Volkswagen AG d
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– The sender wheel is in the correct installation position on the
erm
ab
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
ility
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flange -A- and sender wheel -B-.

wit
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es, in part or in w
t to the co
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– Place caliper gauge on crankshaft flange.

m
at
om
ion
– Measured distance -a- between crankshaft flange and sender

c
in t
or
wheel.
his
ate
do
riv
If dimension -a- is too small:

p
cum
for
en
ng
– Re-press sender wheel ⇒ page 71 .

t.
yi Co
Cop py
t. rig
If dimension -a- is achieved: opyri
gh by
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ht
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– Tighten new sealing flange bolts alternately and diagonally.
lksw
cted agen
Prote AG.

– Install engine speed sender - G28- -arrow-, and tighten bolt.

– Install intermediate plate.
– Install flywheel with new bolts. Tighten bolts.
F - Re-pressing sender wheel
– Secure assembly tool - T10134- to crankshaft flange with hex‐

agon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Push the assembly tool - T10134- against the sealing flange
by hand.
lkswage es n
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– Screw nut -E- onto threaded spindle by hand until it lies
uth against
o
or
assembly housing -C-. ss
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tion in
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AG. Volkswagen AG d
– Tighten nut of assembly tool - T10134- using torque lwrench
wage -
n oes
o ks not
V.A.G 1331- and flared ring spanner tool insert dAF
by 24 - V.A.G
V gu
ara
1332/11- . or
ise nte
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Torque setting au ra
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Nut for assembly tool 40 Nm
rm
ab
pe
ility
ot
– Check the sender wheel installation position on crankshaft
wit
again ⇒ page 70 , is n
h re
hole
spec
If dimension -a- is still too small:
es, in part or in w
t to the co
– Tighten nut of assembly tool - T10134- .
– Check the sender wheel installation position on crankshaft
rrectness of i
again ⇒ page 70
l purpos
Torque settings
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
nform
ercia
61
m
a
com
tio
balance shaft module”, page 155
n in
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page 43
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3 Camshaft
⇒ “3.1 Assembly overview - crankshaft”, page 73
⇒ “3.2 Crankshaft dimensions”, page 74
⇒ “3.4 Measuring axial clearance of crankshaft”, page 74
⇒ “3.5 Measuring radial clearance of crankshaft”, page 75
⇒ “3.6 Renewing needle bearing in crankshaft”, page 75
⇒ “3.7 Renewing spur gear for crankshaft”, page 78
3.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - Bolt
❑ Renew after removal AG. Volkswagen AG d
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❑ 65 Nm +90° by Vol not
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❑ To measure radial clear‐ rise nte
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ance, tighten to 65 a Nm
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but not further. ss
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3 - Bearing cap
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❑ Bearing cap 1: belt pul‐

erm
ab
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❑ Bearing cap 3 with re‐

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cesses for thrust wash‐

hole
spec
ers.
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t to the co
❑ Bearing shell retaining

lugs in cylinder block
and bearing caps must
align.
rrectness of i
4 - Thrust washer
l purpos
❑ For bearing cap 3.

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❑ Note fixing arrange‐

ment.
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5 - Bearing shell 3
n
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❑ For bearing cap without

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ate
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❑ For cylinder block with

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oil groove.
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❑ Do not interchange used bearing shells (mark).
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6 - Needle bearing
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❑ Only vehicles with dual clutch gearbox.
AG.

7 - Camshaft
❑ With toothed belt sprocket for oil pump drive. Toothed belt sprocket is not available as separate part.
❑ Measuring axial clearance ⇒ page 74 .
❑ Check radial clearance with Plastigage ⇒ page 75 .
3. Camshaft 73
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 74 .
8 - Thrust washer
❑ For cylinder block, bearing 3
3.2 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Crankshaft Conrod
sion main journal ∅ journal ∅
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
3.3 Allocation of main bearing shells

Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -A- must be identical on both sides.
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3.4 Measuring axial clearance of crankshaft

erm
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♦ Universal dial gauge holder - VW 387-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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♦ Dial gauge - VAS 6079-

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– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder block as shown in illustration and set
against crank web.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off measured
value.
Axial clearance:
• New: 0.07 ... 0.17 mm
• Wear limit: 0.37 mm
3.5 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Note
♦ Mark used bearings for re-installation but not on bearing sur‐

face.
♦ If bearing shells have worn down to nickel layer, they must be
renewed.
– Remove bearing cap and clean crankshaft journal. AG. Volkswagen AG d

agen oes
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– Place a Plastigage corresponding to the widthisof ed bthe bearing ara
nte
on the journal or into the bearing shells. thor eo
au ra
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• The Plastigage must be in the middle of sthe bearing shell. ce
e
nl
pt
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– Fit bearing cap and tighten. Do not rotate crankshaft.

an
itte
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erm
ab
– Remove bearing cap again.
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– Compare width of Plastigage with the measurement scale.

wit
, is n
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hole
Radial clearance:
spec
es, in part or in w
• New: 0.03 ... 0.08 mm

t to the co
• Wear limit: 0.17 mm.

Torque setting
rrectness of i
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 73

l purpos
3.6 Renewing needle bearing in crankshaft

nf
ercia
or
Only vehicles with a dual clutch gearbox

m
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3. Camshaft 75
♦ adapters - Kukko 22/1-
AG. Volkswagen AG d
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♦ Puller - Kukko 21/2-
erm
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♦ Pin - VW 207 C-
at
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Condition
Note
Vehicles with dual clutch gearbox, the needle bearing must be

installed in rear end of crankshaft.
• Always renew the needle bearing -arrow- after separating en‐

gine and gearbox.
• The front edges of the inner puller must not be chipped.

4-cylinder diesel engine (2.0 l engine,
wagecommon rail) - Edition
e 08.2016 ks s no
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Pulling out needle roller bearing ris
ed
nte
utho eo
– Using a commercially available internal puller, e.ssg.
a KUKKO - ra
c
21/2- , and counter support, e.g. KUKKO - 22/1- , pull needle
ce
e
nl
bearing -1- out of crankshaft -2-.
pt
du
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itte
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– The internal puller must be positioned behind the needle-and-
erm
ab
cage assembly -arrow-.
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es, in part or in w
t to the co
rrectness of i
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Installing
n
c
in t
or
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e
– Clean bearing seat in crankshaft and apply as thin coating of

at
do
riv
grease.
p
cum
for
en
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– Drive needle bearing into crankshaft to installation depth using

n
t.
yi Co
drift - VW 207 C- . Cop py
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Vo
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Prote AG.
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
3. Camshaft 77
3.7 Renewing spur gear for crankshaft

♦ Fitting tool - 10 - 203-
AG. Volkswagen AG d
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ab
♦ Tapered roller bearing puller - T10392-
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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atio
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♦ Press tool - T10392/1-

o
n in
or c
thi
e
♦ Temperature gauge - VAS 6519- or hand-held multimeter -

t
sd
iva
V.A.G 1526D- in combination with temperature sensor - V.A.G
o
r
rp
cu
1526D/1-
o
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♦ Commercially available hotplate t. Cop py
rig
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– Remove sealing flange (belt pulley end) ⇒ page 57 .
– Remove balancer shaft module ⇒ page 181

Pulling off spur gear

– Insert thrust piece - T10392/1- in crankshaft stub.
AG. Volkswagen AG d
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– Insert puller - T10392- into holes of spur gear and turn clock‐
es, in part or in w
wise -arrow-. Screw in locating pins -A-.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
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iva
do
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rp
– Counterhold crankshaft with ring spanner -A-, pull spur gear

um
fo
off crankshaft journal by screwing spindle in using ring span‐

en
ng
t.
yi
ner -B- or ratchet.
Co
Cop py
ht. rig
ht
Shrink-fitting spur gear
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
♦ Check temperature when heating the new drive pulley using

temperature gauge - VAS 6519- or hand-held multimeter -
V.A.G 1526D- in combination with temperature sensor - V.A.G
1526D/1- . To do this, push measuring tip of temperature sen‐
sor onto drive pulley.
♦ At a temperature of 200 °C, the drive pulley must be driven
onto crankshaft within approx. 4 seconds.
♦ A higher temperature increases the available time (220 °C =
approx. 6 seconds).
♦ Ensure that crankshaft stub is clean.
Caution
The maximum temperature of 240 °C must not be exceeded

because this will lead to discolouring and possibly distortion of
the drive pulley.
3. Camshaft 79
AG. Volkswagen AG d
agen oes
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California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ➤ d b, Transporter 20 ...
y gu
ara
ise nte
4-cylinder diesel engine (2.0 l engine, common rail)th-o Edition 08.2016
r eo
au ra
ss c
– Place new spur gear onto a commercially available hot plate
ce
e
nl
pt
and heat to at least 200 °C, maximum 240 °C. The lettering
du
an
itte
faces upwards.
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erm
ab
ility
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WARNING
wit
, is n
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hole
spec
Risk of burns. Wear suitable protective gloves for further work.
es, in part or in w
t to the co
rrectness of i
l purpos
– When the temperature is reached, take spur gear up using
nf
ercia
pliers, as shown in illustration.
orm
m
atio
om
n in
Note
or c
thi
te
sd
iva
Take care not to damage the teeth of the spur gear.
o
r
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en
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
– Slide spur gear quickly by hand without canting onto crank‐

shaft end until stop using fitting tool - 10 - 203- .
– Allow the spur gear to cool down a few minutes and then install
balancer shaft module ⇒ page 181 .
Torque settings
page 43
♦ ⇒ “4.1 Removing and installing balance shaft module”,
page 181

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 81
⇒ “4.2 Separating new conrod”, page 83
⇒ “3.3 Allocation of main bearing shells”, page 74
⇒ “4.3 Checking pistons and cylinder bores”, page 84
⇒ “4.4 Checking radial clearance of conrods”, page 85
⇒ “4.5 Measuring piston projection at TDC”, page 85
⇒ “4.6 Removing and installing oil spray jets”, page 87
4.1 Assembly overview - pistons and conrods
1 - Conrod bolt
❑ Oil threads and contact
surface.
❑ Use old bolt for measur‐
ing radial clearance.
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The caps only fit in one
position and only on the
AG. Volkswagen AG d
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not
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to the breaking proce‐ byV
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ara
dure (cracking) separat‐ rised
nte
ing the cap from the autho eo
ra
conrods. ss c
ce
e
❑ Mark cylinder allocation

nl
pt
du
an
in colour -B-.
itte
y li
erm
ab
❑ Installation position:
ility
ot p
markings -A- face to‐

wit
, is n
wards belt pulley end.

h re
hole
3 - Sleeve bearing
spec
es, in part or in w
❑ Fitting position
t to the co
⇒ page 74
❑ Mark used bearing
rrectness of i
shells for re-installation

but not on bearing sur‐
l purpos
face.
❑ Renew bearing shells
nform
ercia
worn down to base lay‐

er.
m
at
om
❑ Note version: upper

ion
c
bearing shell (towards

in t
or
his
e
piston) made of a more

at
do
riv
wear-resistant material.
p
cum
Identification on new
for
en
g
bearing shells: black line on bearing surface in area of joint

n
t.
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op py
❑ Ensure firm seating.
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4 - Connecting rod
co Vo
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❑ Renew as set only.
AG.
❑ With industrially cracked conrod bearing cap

❑ Separate new conrod ⇒ page 83
❑ Mark cylinder allocation in colour -B-.
4. Pistons and conrods 81

❑ Installation position: markings -A- towards belt pulley end
❑ Axial clearance, wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 85
5 - Locking ring
AG. Volkswagen AG d
❑ Renew after removal agen oes
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6 - Piston pin orise nte
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❑ If difficult to move, heat piston to approx.s60°C.
au ra
c
s
❑ Remove and install using drift - VW 222 A- .
ce
le
un
pt
an
d
7 - Piston
itte
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ab
❑ With combustion chamber. pe
ility
ot
❑ Mark installation position and cylinder number ⇒ page 85 .
wit
, is n
h re
❑ Checking ⇒ page 84
hole
spec
❑ Install using piston ring clamp.
es, in part or in w
t to the co
❑ Piston and cylinder dimensions ⇒ page 84 .
❑ Measuring cylinder bore ⇒ page 84
rrectness of i
❑ Measuring piston projection at TDC ⇒ page 85 .
l purpos
8 - Piston rings
❑ Compression rings
nform
ercia
❑ Offset gaps by 120°.

m
❑ Use piston ring pliers to remove and install.
a
com
tio
❑ Installation position: marking “TOP” or side with lettering towards piston crown
n in
r
te o
thi
❑ Checking ring gap ⇒ page 82 .
s
iva
do
r
❑ Checking ring-to-groove clearance ⇒ page 83 .

rp
cum
fo
en
g
9 - Piston ring
n
t.
yi Co
op py
❑ Oil scraper ring
t. C rig
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❑ Offset gaps by 120° relative to lower compression ring. cop Vo
by lksw
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❑ Use piston ring pliers to remove and install. Prote AG.
❑ Checking ring gap ⇒ page 82 .

❑ Checking ring-to-groove clearance ⇒ page 83 .
Checking piston ring gap

♦ Feeler gauge
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 to 0.40 1.0


dimensions in mm
2nd compression ring 0.20 to 0.40 1.0
Oil scraper ring 0.25 to 0.50 1.0
Checking ring-to-groove clearance
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1st compression ring 0.06 to 0.09 0.25
2nd compression ring 0.05 to 0.08 0.25
rrectness of i
Oil scraper ring 0.03 to 0.06 0.15
l purpos
4.2 Separating new conrod
nform
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– Clamp conrod -1- below dashed line.

– Unscrew bolts -2- approx. 5 turns.

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -1- in direction of -arrow- until it is loose.
4.3 Checking pistons and cylinder bores

Checking piston
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
ton pin axis with a 75 to 100 mm external micrometer.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension ⇒ page 84
Note
Piston must be renewed if piston shaft reveals cracking.
AG. Volkswagen AG d
Checking cylinder bores lksw
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♦ Cylinder gauge 50 to 100 mm

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-A- and longitudinal direction -B-.

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Note
Cylinder bores must not be measured when the cylinder block is

secured to engine and gearbox support - VAS 6095A- , as meas‐
urements may be incorrect.
Installation position and allocation of piston to cylinder

Arrow on piston crown -arrows- points in direction of cylinder 1.
Piston ∅ Cylinder bore ∅
Basic di‐ mm 80.96 81.01
mension
4.4 Checking radial clearance of conrods

♦ Plastigage
– Remove conrod bearing cap. Clean bearing cap and bearing
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– Place a Plastigage corresponding to the widthyV
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Radial clearance:
, is n
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• Wear limit: 0.08 mm
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– Renew conrod bolts.

Torque setting t to the co
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Conrod bearing cap 30 Nm
4.5 Measuring piston projection at TDC

nform
mercia

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♦ Measuring tool - VW 382-

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♦ Measuring plate - VW 385/17-
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Test sequence
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agen
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head gasket according to following table.
♦ Turn the engine in an clockwise direction to carry out the
measurement.
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate - VW 385/17- to cylinder block
as shown in illustration.

– Measure the projection of each piston at the two points marked

with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
– Install the appropriate cylinder head gasket wdepending
agen
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♦ Holes = arrow 2
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♦ Production control code = arrow 3 (can be disregarded)
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4.6 Removing and installing oil spray jets


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– Turn crankshaft in direction of engine rotation until respective

pressure relief valve and oil spray jets are accessible.
nform
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Caution
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Risk of damage to oil spray jets caused by deformation.
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– Unscrew pressure relief valve -1- using Torx bit T40 - gh ht
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– Remove oil spray jets -2-.
Installing
– Align guiding edge of oil spray jet with machined surface of
cylinder block.
Torque settings
Oil spray jet with 24 Nm
pressure relief
valve

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⇒ “1.1 Assembly overview - cylinder head”, page 89
h re
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spec
⇒ “1.2 Assembly overview - cylinder head cover”, page 92
es, in part or in w
t to the co
⇒ “1.3 Removing and installing cylinder head”, page 96
⇒ “1.4 Removing and installing cylinder head cover”, page 107
rrectness of i
⇒ “1.5 Removing and installing injector seals”, page 112
l purpos
⇒ “1.6 Removing and installing vacuum pump”, page 116

⇒ “1.7 Checking compression”, page 118
nform
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1.1 Assembly overview - cylinder head

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1. Cylinder head 89
1 - Cylinder head
❑ If there is no pipe con‐
nection fitted on the new
cylinder head, install it to
the new cylinder head
⇒ page 96 .
❑ For information on the
pipe connection and sil‐
icone adhesive sealant ,
refer to ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ After renewing, renew
entire coolant.
❑ Check for distortion
⇒ page 91 .
❑ Checking compression
⇒ page 118 .
⇒ page 96
2 - Washer
3 - Cylinder head bolt
❑ Observe sequence for
loosing and tightening
⇒ page 96
❑ Before installing, place
washers in cylinder
head
⇒ Item 2 (page 90) .
4 - Oil pressure switch - F1-
❑ Identification: green
❑ 0.5 bar
❑ If seal is leaking, nip n AG. Volkswagen AG do
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❑ 18 Nm
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8 - Seal
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Rep. gr.15 - Cylinder head, valve gear cted agen
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9 - Vacuum pump
DANGER!
The vacuum pump may,
under no circumstances,
be dismantled as the
vacuum part could other‐
wise malfunction. This
would result in failure of
the brake servo.

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10 - Bolt yV
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❑ 10 Nm horis tee
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11 - Clip ss
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12 - Radiator outlet coolant - G62-
an
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13 - Sealing ring
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14 - Bolt
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❑ 10 Nm
15 - Coolant hose connection
16 - Seal rrectness of i
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17 - Bolt
nform
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❑ 25 Nm
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18 - Lifting eye
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19 - Cylinder head gasket

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20 - Hall sender - G40- yri
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❑ Removing and installing ⇒ page 508 cted agen
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21 - Bolt
❑ 10 Nm
Checking cylinder head for distortion
1. Cylinder head 91
♦ Straightedge 500 mm - VAS 6075-

♦ Feeler gauge -1-
Max. permissible distortion: 0.1 mm
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection at TDC must be determined when installing
new pistons or a short engine ⇒ page 85 .
AG. Volkswagen AG d
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92 Rep. gr.15 - Cylinder head, valve gear

1 - High-pressure accumulator
(rail)
❑ Comply with rules for
cleanliness ⇒ page 10 .
❑ Do not attempt to re‐
shape high-pressure
lines.
high-pressure lines
⇒ page 406 .
2 - Bolt
❑ 22 Nm
3 - Fuel return pipe
❑ Route fuel return lines in
noise insulation guides agen
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❑ To fuel tank
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❑ The fuel return line must
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hole
spec
❑ Remove ⇒ page 95
es, in part or in w
t to the co
❑ Check fasteners
⇒ page 95
❑ Attach ⇒ page 95
rrectness of i
❑ Lock ⇒ page 96
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4 - Injector (piezo injectors)
nform
ercia
WARNING
m
a
Only cleaning set - VAS
com
tion in
6811- may be used for
r
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cleaning the sealing sur‐ s
iva
face of the injector bore.

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to the ⇒ operating man‐
ual provided with the
cleaning set - VAS
6811- .
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”,
“O-ring for injector bore”, “O-ring for injector return connection”.
❑ If they are to be re-installed, the injectors must always be re-fitted on the same cylinder.
❑ Before re-using “high-pressure pipe”, perform visual check of taper seats for damage such as transverse
scores or corrosion. Always renew pipe if damaged.
5 - O-ring
6 - Bolt
1. Cylinder head 93
gen AG
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swage➤ , Multivan
n AG does 2010 ➤ , Transporter 20 ...
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4-cylinder diesel
y Volkengine (2.0 l engine, common not rail) - Edition 08.2016
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❑ 8 Nm +270° tho e or
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7 - O-ring ss
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8 - Sealing ring
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9 - Clamping plate
hole
spec
10 - Noise insulation
es, in part or in w
t to the co
❑ Route fuel return lines ⇒ Item 3 (page 93) in noise insulation guides.
11 - Injector seal
rrectness of i
❑ Renew if damaged or leaking ⇒ page 112 .
l purpos
12 - Sealing cover
13 - Seal
nform
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14 - Grommet
m
at
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io
15 - Bolt
n
c
in t
or
❑ Renew if seal is damaged
his
ate
do
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❑ Tightening sequence ⇒ page 96

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17 - Vacuum hose
AG.
18 - Cylinder head cover

19 - O-ring
❑ Renew if damaged or leaking
20 - Pipe line
❑ For crankcase ventilation.
❑ Press release buttons to remove.
21 - Sealing bush for fuel rail
22 - Grommet
23 - Bolt
❑ 10 Nm

Disconnecting fuel return lines

– With engine switched off, carefully pull return line connections
off injectors. To do this, press both clips downwards
-arrow A- and simultaneously pull release pin upwards
-arrow B-.
Check catches
Caution
• Carefully pull fuel return lines upwards when disconnect‐

ing as the 4 catches -arrow- can fracture.
• After disconnecting, check the 4 catches -arrow- to see
whether they are fractured or have broken off.
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• Always replace
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• A damaged
ris fuel return line that becomes loose
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Attach fuel return line

t to the co
– Apply a thin coat of diesel fuel to new O-rings on return-line

connections.
rrectness of i
– Attach fuel return line and press the two clips downwards as
l purpos
far as they will go -arrows-.

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1. Cylinder head 95
Lock fuel return line

– After fuel return line has been pushed on completely, press
locking pin downwards -arrow-.
AG. Volkswagen AG d
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Tightening sequence for cylinder head cover
spec
– Hand-tighten cylinder head cover in the sequence -1 … 6-.
t to the co
rrectness o
cial p
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1.3 Removing and installing cylinder head

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equipment required
♦ Guide bolt - 3070-
♦ Remove diesel injection
pump locking pin - 3359-
(qty. 2).
♦ Crankshaft stop - T10050-
♦ Retainer - T10051-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
lkswage es n
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1. Cylinder head 97

1331-
♦ Socket set 1/4", 22-piece -
VAS 5528-
VAS 6122-
- VAS 6208-
VAS 6362- AG. Volkswagen AG d
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Prote AG.
♦ Before carrying out further work, remove the battery. There‐

fore, first check whether a coded radio is fitted. Obtain anti-
theft coding beforehand if necessary.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
♦ Collect drained coolant into a clean container for re-use or
disposal.

Caution

itations:
is re-established.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.
AG. Volkswagen AG d
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Note
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spec
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♦ Cylinder head is removed together with transport eyelet -1-,

t to the co
vacuum pump -2-, pipe -3-, oil pressure switch - F1- -4- and
union -5-. If necessary, these parts must be removed with the
cylinder head removed.
rrectness of i
♦ Glow plugs -arrows- project out of cylinder head. After remov‐

l purpos
al, the cylinder head must not be placed on the glow plugs. If
necessary, remove glow plugs ⇒ page 502 .
nf
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Removing
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– Disconnect battery earth strap with ignition switched off ⇒

o
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Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐

or
thi
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ing battery .
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– Remove camshaft sprocket from hub.
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– Remove camshaft hub. To do this, pull camshaft hub off using yri
p by
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puller - T10052- .
c by lksw
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1. Cylinder head 99
– Counterhold hub with counterhold - T10051- and release hub

bolt -1-.
– Unscrew hub bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.

– Tighten bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft. Hold puller with 30 mm
spanner whilst doing this. olks
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– Remove hub from taper of camshaft. db ara
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– Unscrew bolt -arrow- from toothed belt guard.
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– Screw off Hall sender - G40- -arrow-.

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– Remove turbocharger ⇒ page 298 .
AG. Volkswagen AG d
agen
Vehicles with “single turbo engine” Volksw
oes
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– Remove turbocharger ⇒ page 273or.ise nte
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– Remove exhaust gas recirculation
ss a
cooler ⇒ page 485 . c
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– Pull back heat shield -arrow-.
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– Release connector -4- and pull off. s
iva
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– Remove cylinder head cover ⇒ page 107 .

um
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– Remove intake manifold ⇒ page 437 .
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– Detach vacuum line -2- from vacuum pump -1-.
1. Cylinder head 101

– Disconnect connector -4- at coolant temperature sender -

G62- .
– Securing clip -3- remains fitted on flange.
– Pull off securing clip -2- and separate coolant line -1-.
AG. Volkswagen AG d
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– Open spring-type clip -2- and pull off coolant hose
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– Open spring-type clips -1- and -3- and pull off coolant hoses
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-2- and -4-.

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– Open spring-type clip -1- and pull off coolant hose -2-.
– Observe correct sequence when loosening cylinder head

bolts.
AG. Volkswagen AG d
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♦ A second mechanic is required to remove and install the cyl‐
erm
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inder head.
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♦ Before removing cylinder head, remove toothed belt tension‐
h re
hole
ing roller from stud. Make sure that toothed belt tensioning
spec
roller does not fall to the floor.
es, in part or in w
t to the co
♦ Check that all necessary hoses and lines have been discon‐
nected.
rrectness of i
♦ Do not place cylinder head onto dowel sleeves -A- when re‐
moving and installing.
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– First raise cylinder head on gearbox side and pull slightly to

nf
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left. Whilst doing this, remove toothed belt tensioner from stud.
orm
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atio
– When lifting cylinder head out, guide electrical lines and cool‐
om
ant hoses past transport eyelet.

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Caution
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Risk of damage to glow plug pins -arrow- when cylinder head
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♦ Do not lay removed cylinder head with installed glow plugs
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down on sealing surface, as glow pins -arrow- project past Prote AG.
sealing surface.

Caution
Risk of damage to sealing surfaces!

♦ When using abrasive paper do not use a grade less than
100.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove remains of emery and abrasives.
Note
If the cylinder head is renewed, then parts which remained on the

cylinder head when it was removed must consequently be trans‐
ferred.
Installing
Caution
Risk of damage to cylinder block!

♦ No oil or coolant may be contained in hole pocketsolkfor
swacyl‐
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inder head bolts in cylinder block. d byV ua
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Danger of cylinder head gasket leaks! utho or
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♦ Do not remove new cylinder head gasket from packaging
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damage to the silicone coating or the indented area of the ility
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Risk of damage to open valves.

hole
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♦ When installing an exchange cylinder head, the plastic

t to the co
protectors fitted to protect the open valves should not be

removed until the cylinder head is ready to be fitted.
rrectness of i
Risk of damage to valves and piston crowns after working on

valve gear.
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♦ Turn the crankshaft carefully at least 2 rotations to ensure

that none of the valves make contact when the starter is
nf
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operated.
orm
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Note
♦ Proceed with extreme caution. The assistance of a second

mechanic is vital.
♦ Always renew cylinder head bolts.
♦ Renew seals, gaskets, self-locking nuts,
swa
bolts tightened
gen AG
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does
through an additional specified angle
by
Voland clamps.
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♦ Do not remove new cylinder theadho
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it is ready to be fitted. au ra
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♦ If an exchange cylinder head is installed, contact surfaces be‐

nl
pt
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tween roller rocker fingers and running surface of cam must
an
itte
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be oiled.
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ility
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♦ Hose unions and air intake pipes and hoses must be free of
wit
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oil and grease before installation.
h re
hole
spec
♦ When renewing cylinder head or cylinder head gasket, entire
es, in part or in w
coolant ⇒ page 187 and engine oil ⇒ Maintenance ; Booklet
t to the co
19 must be replaced.
Renewing cylinder head:
rrectness of i
♦ If there is no pipe connection fitted on the new cylinder head,
l purpos
install it to the new cylinder head.

♦ For information on the pipe connection and silicone adhesive
nf
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o
sealant , refer to ⇒ Electronic Parts Catalogue (ETKA) .
rm
m
atio
m
– Insert pipe connection with silicone adhesive sealant into cyl‐

o
n in
c
inder head.
or
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– Use a suitable tool to drive pipe connection into cylinder head.

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Continuation:
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– To centre, screw guide pins -3070/9- into outer threaded holes
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on intake side. cop Vo
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• Cylinder head gasket installation position: marking “top” or
AG.
part number towards cylinder head

– Position cylinder head gasket.
– Guide cylinder head into toothed belt guard and push tension‐
ing roller onto stud. When doing this, cylinder head must not
scrape over dowel sleeves -A-.
– Fit cylinder head.
– Insert 8 cylinder head bolts and screw in by hand until contact
is made.
– Unscrew guide pins -3070/9- through bolt holes in cylinder
head and screw remaining cylinder head bolts by hand until
contact is made.

Cylinder head bolt tightening sequence

– Tighten cylinder head in 4 stages in sequence shown as fol‐
lows:
1- Tighten initially with torque wrench:
Stage I = 35 Nm
Step II = 60 Nm
2- Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)

Further assembly is carried out in the reverse order. During this
step, observe the following:
– Secure bolt -arrow- of toothed belt guard. agen

AG. Volkswagen AG d
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– Install hub and camshaft sprocket. ed by ara
nte
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Note
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The bolts for the camshaft sprocket must be renewed.
y li
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ab
ility
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– Install toothed belt ⇒ page 122 .
wit
is n
h re
ole,
spec
– Installing turbocharger ⇒ page 298 .
t to the co
– Installing turbocharger ⇒ page 284 .
rrectne
– Install exhaust gas recirculation cooler ⇒ page 492 .
ss
o
cial p
– Install particulate filter ⇒ page 474 . f inform

mer
atio
m
– Install cylinder head cover ⇒ page 107 .

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Prote AG.

– Screw on Hall sender - G40- -arrow-.

– Install intake manifold ⇒ page 437 .
– Reconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
♦ If components of fuel system between fuel tank and high-pres‐
sure pump are unbolted, removed or renewed, “Bleeding fuel
system” function must be carried out to bleed fuel system us‐
ing ⇒ Vehicle diagnostic tester.
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in the process. The process must not be ter‐
minated prematurely. gen AG
. Volkswagen AG
d wa oes
olks not
– Carry out road test and read all event memories.
db
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Torque settings utho eo
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 89
ce
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an
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 273
d
itte
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ab
♦ ⇒ “3.1 Assembly overview - exhaust gas recirculation”,
pe
ility
page 482
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hole
spec
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 437
es, in part or in w
t to the co
1.4 Removing and installing cylinder head
rrectness of i
cover
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Observe safety precautions ⇒ page 2 .

Comply with rules for cleanliness ⇒ page 10 .
nform
ercia
Observe system overview ⇒ page 371 .

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Assembly overview - fuel system ⇒ page 373 .
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♦ Multi-point bit - T40055-
Removing
G. Volkswagen AG d
Vehicles with “bi-turbo lengine”:
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agen
A
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– Remove connecting
ris
ed
b
pipe ⇒ page 336 ara
nte
tho eo
Continued for
s a all vehicles:
u ra
c
s
ce
e
– Detach wiring harness -2- from toothed belt guard -3-.

nl
pt
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an
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– Open clips -1- and remove toothed belt guard -3-. y li

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ility
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c
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ate
do
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for
en
– Detach coolant hose at cylinder head cover -arrows-.

ng
t.
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– Remove pipe from cylinder head cover -arrow-.
– Pull vacuum hose -arrow- off from cylinder head cover.
AG. Volkswagen AG d
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– Unscrew bolts -3-. s
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– Unscrew union nuts -1- using socket - T40055- and remove

an
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fuel line -2-.

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– Place removed high-pressure line on a clean surface.

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spec
t to the co
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mer
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c
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– Release connector -1- and pull off from fuel pressure sender
fo
en
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- G247- -2-.
t.
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– Pull cable guide -3- from fuel rail.
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– Release all connectors -1- and pull off from injectors (piezo
injectors).
– Detach clip -2-.
– Release connector -4- and pull off from fuel pressure regulat‐
ing valve - N276- -3-.
– Maintain cleanliness. No dirt must be allowed to get into dis‐
connected return lines, fuel lines or injector connections.
Caution

• Always replace damaged fuel return lines.
• A damaged fuel return line that becomes loose when en‐
gine is running causes damage to injection valve (piezo
injector). The injection valve (piezo injector) must then be n AG. Volkswagen AG do
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spec
-arrow B-.
t to the co
rrectness o
cial p
f inform
mer
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n
c
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or
n thi
te
sd
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fo
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t.
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Cop py
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cted agen
Prote AG.

– Pull all fuel return lines -1- off injectors (piezo injectors).
– Unscrew all union nuts -2- from injectors (piezo injectors).
– Open clip -5- and detach fuel hose -4- from high-pressure ac‐
cumulator (fuel rail).
– Unscrew bolts -6- from fuel rail.
– Remove fuel rail -3- to right. Guide fuel return line -arrow- past
fuel lines when doing this.
– Maintain cleanliness. No dirt may get into the injector holes on
the cylinder head cover.
– Remove injectors (piezo injectors) ⇒ page 412 .
– Remove noise insulation.
– Unscrew cylinder head cover bolts in sequence -6 … 1- and

remove cylinder head cover.
Installing
WARNING
For vehicles with solenoids, the learnt values from the fuel sys‐
tem must be reset following the renewal of the fuel pressure
regulating valve - N276- ⇒n AVehicle
wage
G. Volkswdiagnostic
agen AG
doe tester.
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– Apply aautthin
ho coat of diesel fuel to new O-rings on return-line
eo
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connections.
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tion in
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thi
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lkswage es n
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spec
es, in part or in w
t to the co
– First, hook back of top part of toothed belt guard to middle part
-1- of toothed belt guard.
rrectness of i
– Then, fit toothed belt guard to middle -2- and -3- of toothed belt
l purpos
guard at the top.

nform
ercia
m
at
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ion
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♦ This process takes 130 seconds. Fuel pumps are actuated a Cop py
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total of 3 times in the process. The process must not be ter‐ yri
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minated prematurely. cop Vo
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Torque settings
AG.
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 92

♦ ⇒ “1.3 Assembly overview - fuel system”, page 373
1.5 Removing and installing injector seals


equipment required
♦ Assembly tool - T10208/2-
♦ Lambda probe open ring
spanner set - 3337-
♦ Tool set - T10055-
♦ Seal puller - T40195-
1331-
♦ Tool set - T10133-
AG. Volkswagen AG d
agen oes
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
r
♦ Injector remover - T10402-

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Removing
Note safety precautions ⇒ page 2 .
Observe rules for cleanliness ⇒ page 10 .

– Maintain cleanliness. No dirt must be allowed to get into dis‐

connected return lines, fuel lines or injector connections.
Caution

injector). The injection valve (piezo injector) must then be
replaced.

-arrow B-.
– Remove only injectors whose injector seal is to be renewed
– Remove noise insulation at injectors. AG. Volkswagen AG d
agen oes
olksw not
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ara
Caution rised
nte
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You must therefore proceed very carefully in order to avoid ss c
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unnecessary assembly work or further damage.

nl
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Maintain cleanliness. No dirt may get into the injector holes on

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the cylinder head cover.
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First remove leaked oil or fuel with workshop equipment. wit

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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

– Position puller - T10055- with injector remover - GT10402-

A . Volkswag-1-
en
and -2- as shown and pull injectors out agen by tapping. AG does
upwards
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– Screw oil seal extractor - T40195-
or
ise forcibly as far as possible nte
into seal by hand. au
th eo
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Pull injector seal upwards by tapping gently using oil seal extrac‐
ce
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un
pt
tor - T40195- , adapter - T101333/2- and slide hammer -
an
d
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T10133/3- .
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pe
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– After removal, check whether the spring washer is still on the
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old seal.
, is n
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hole
If not, check that spring washer does not remain in injector shaft.
spec
es, in part or in w
Installing
t to the co
rrectness of i
Caution
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You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
nform
ercia
Remember that the cylinder head cover is made of plastic.

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tion in
A plastic cylinder head cover is damaged easily during repairs.
r
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Check cylinder head cover for damage.
iva
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t.
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– Initially position new injector seal by hand. ht. Cop py
rig
rig ht
– Then carefully push new injector seal in to stop using assem‐ py by
co Vo
bly tool - T10208/2- .
by lksw
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Continue assembly in reverse order of dismantling.
connections.


minated prematurely.
Torque settings
1.6 Removing and installing

agen
vacuum
AG. Volkswagen AG
do
pump
w es n
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d b equipment required
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♦ Torque wrench -utV.A.G
ho 1410- or
a ac
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ility
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t to the co
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♦ Hose clamp pliers - VAS 6340-

nf
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orm
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Prote AG.
DANGER!
The vacuum pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction. This
would result in failure of the brake servo.

Removing
– Unscrew bolts -3-. AG. Volkswagen AG d
agen oes
lksw not
– Move coolant expansion tank -2- aside slightly
d by
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ara
hoses still attached. orise nte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.
– Pull clip -2- out of bracket.

– Unscrew bolt -1-. Pull exhaust pressure sensor 1 - G450- -3-
out of bracket.

– Open spring-type clips -2- and pull off hoses -1-.

– Unscrew bolt -4- and remove retainer -3-.
– Unscrew bolt -5- until retainer -6- can be rotated downwards.
lkswage es n
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byV ua
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ir se tee
tho
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un
pt
an
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– Detach vacuum line -2- from vacuum pump -1-.
rm
ab
pe
ility
– Place cloths under vacuum pump -1-.
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unscrew vacuum pump bolts -arrows-.

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tion in
– Remove vacuum pump from cylinder head.
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Installing
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♦ Ensure that vacuum pump coupling seats properly in cam‐
AG.
shaft.
♦ Vacuum pump has been correctly seated in camshaft if it is
lying completely against cylinder head.
♦ The seal must be renewed.
Torque settings
1.7 Checking compression


♦ Compression tester - V.A.G 1763-
Check condition
• Engine oil temperature min. 30°C
Test sequence
– Pull connectors off the injectors. n AG. Volkswagen AG do
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– Remove glow plug from respective scylinder
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– Screw in adapter - V.A.G 1763/8- in place of the glow plugs.
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V.A.G 1763- .
t to the co
– Check compression using compression tester - V.A.G 1763- .
Using compression tester ⇒ operating instructions .
rrectne
– Start engine until tester shows no further pressure increase.
Compression pressures:
ss o
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New: 25 to 31 bar
inform
mer
Wear limit: 19 bar

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Permissible difference between all cylinders: 5 bar

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– Install glow plugs using U/J extension and 10 mm socket -

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3220- ⇒ page 502 .

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– Reconnect connectors of injectors.

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2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 120
⇒ “2.2 Removing and installing toothed belt”, page 122
2.1 Assembly overview - toothed belt
1 - Toothed belt
❑ Check for wear
❑ Do not kink.
⇒ page 122
2 - Bolt
❑ Use counterhold - 3415-
to loosen and tighten.
❑ Do not additionally oil or
grease the threads and
shoulder.
❑ Turning further can be
done in several stages.
❑ 180 Nm + 135°
3 - Crankshaft pulley
4 - Nut
❑ 20 Nm
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8 - Bolt
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❑ 20 Nm + 45°
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9 - Camshaft sprocket
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10 - Bolt
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❑ 20 Nm
11 - Bolt
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❑ 100 Nm
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12 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
nform
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❑ To remove, use puller - T10052-

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13 - Rear toothed belt guard

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❑ 10 Nm
16 - Idler roller
17 - Bolt
❑ 50 Nm + 90°
18 - Hub
❑ Use counterhold - T10051- to loosen and tighten.
❑ To remove, use puller - T40064- .
19 - Nut
❑ 95 Nm
20 - Toothed belt pulley on high-pressure pump
21 - Bolt
❑ 20 Nm + 90° AG. Volkswagen AG d
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22 - Coolant pump d by V gu
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❑ Removing and thor installing ⇒ page 225 eo
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23 - Bolt ss
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❑ 15 Nm
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24 - Toothed belt guard upper part
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25 - Toothed belt guard lower part wit

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26 - Toothed belt guard centre part
hole
spec
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27 - Bolt
t to the co

❑ 10 Nm
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28 - Bolt
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❑ 10 Nm + 90°
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29 - Belt pulley and vibration damper

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30 - Bolt
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31 - Protective plate C py
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32 - Bolt
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❑ Note tightening sequence ⇒ page 34

❑ Specified torque ⇒ page 35 .
33 - Engine support

Stud for tensioning roller. 15 Nm
2. Toothed belt drive 121

4-cylinder diesel engine (2.0 l engine, common rail) - Edition 08.2016. Volkswage
AG n AG d
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2.2 Removing and installing toothed belt ise
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♦ Remove diesel injection
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pump locking pin - 3359-
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♦ Crankshaft stop - T10050-
hole
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♦ Angled screwdriver -
T10264-
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♦ Bit - T10265-
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♦ Angled screwdriver - T10409-
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2 versions of tensioning roller are fitted. Theyhoare
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♦ Check tensioning roller is seated correctly in timing belt guard.
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♦ Tension toothed belt by turning tensioning roller eccentric

»clockwise«
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Observe different directions of rotation during tensioning

Features of tensioning roller A:
♦ Locking tool - T10265- required for installation.
♦ Check tensioning roller iseseated
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♦ Tensioning roller is not seated in toothed belt guard.
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♦ Tension toothed belt by rotating tensioning roller eccentric
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Removing
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Note
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Always carry out adjustment work on toothed belts only when the
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– Loosen clamp -2-.

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– Pull off intake hose -3-.

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– Remove expansion tank for hydraulic fluid and lay aside.

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– Lift retaining clip (not visible in picture) and pull off pressure
hose -1- from charge air cooler.


Vehicles with bi-turbo engine
– Detach connecting hose on pulsation damper and lay aside.

– Open clips -1- and remove toothed belt guard.
– Remove vibration damper ⇒ page 54 .
– Relax poly V-belt tensioning element.
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– Remove lower toothed belt guard. To do so, remove bolts

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-arrows-.
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spec
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– Turn engine to TDC and lock crankshaft pulley in position with

crankshaft stop - T10050- . Fit the crankshaft stop in the teeth
from the face side of the toothed belt pulley.
• The mark -2- on the toothed pulley and the arrow -1- on the
crankshaft stop - T10050- must align -arrow-. When doing this,
the pin of the crankshaft stop -arrow- must engage in the seal‐
ing flange hole.
The arrow on the camshaft pulley -1- must point to almost »12
o'clock« when doing this.
– Mark direction of rotation of toothed belt -3-.
– Loosen bolt -2-
AG. Volkswagen AG d
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Tensioning roller A:
wit
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spec
es, in part or in w
t to the co
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– Loosen nut of tensioning roller -1- and turn tensioning roller

eccentric using socket - T10264- in anti-clockwise direction
-arrow- until tensioning roller can be locked with locking pin -
T10265- .
– Turn tensioning roller eccentric clockwise -arrow- as far as

stop. Tighten nut -1- hand-tight.
Tensioning roller B:
AG. Volkswagen AG d
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4-cylinder diesel engine (2.0 l engine, common rail) - Edition
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– Loosen tensioning roller nut -1-. ris tee
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– Use angle driver - T10409- to rotate eccentric -2- ofstensioning
s
roller clockwise -arrow- until tensioning roller is relieved of
ce
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– Only hand-tighten nut -1-.
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maining toothed pulleys.
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Continuation for both tensioning rollers
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Caution
rrectne
Risk of irreparable damage if direction of rotation is reversed
on previously used toothed belt.
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♦ Before removing toothed belt, mark direction of rotation
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with chalk or felt tipped pen for installation purposes.
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– First remove toothed belt from camshaft sprocket and then
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from the other sprockets.
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♦ Always carry out adjustment work on toothed belts only when

the engine is cold, as the indicator position on the tensioning
element varies depending on the engine temperature.
♦ If the tensioning roller is to be renewed, the engine support
must be removed ⇒ page 38 .
♦ Renew bolts for camshaft pulley and high-pressure pump pul‐
ley.
• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• Crankshaft is locked using crankshaft stop - T10050- .

• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• Crankshaft is locked using crankshaft stop - T10050- .
Tensioning roller B:
– Set tensioner of tensioning roller to 9 o'clock position.

– Attach tensioning roller provisionally.
Crankshaft is locked using crankshaft stop - T10050-G. . Volkswage

A n AG d
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Continuation for both tensioning rollers olksw not
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an
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adapters - T10172/4- until camshaft hub can be secured in posi‐
rm
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tion. To do this, hand-tighten at least one bolt -1-.

pe
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– Fix the hub in place with locking pin for diesel injection pump
- 3359- . To do this, insert locking pin through outer free elon‐
gated hole into hole in cylinder head.
rrectness of i
– Loosen hand-tightened bolts again.

l purpos
nform
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Note
m
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com
Turn hub of high-pressure pump at bolt heads with screwdriver

tion in
until hub can be secured in position.

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– Secure high-pressure pump with locking pin for diesel injection
on in
pump - 3359- . To do this, push locking pin into adjustment
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hole outside toothed belt pulley.
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It should just be possible to turn high-pressure pump toothed belt
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– Turn camshaft pulley -3- and toothed belt pulley of high-pres‐

sure pump -5- in their elongated holes clockwise to stop.
– Fit toothed belt in sequence described:
1- Crankshaft pulley
2- Tensioning pulley
3- Camshaft toothed belt pulley
4- Coolant pump toothed belt pulley
5- High-pressure pump toothed belt pulley
6- Idler roller
– Undo the nuts of the tensioning roller and pull out locking tool
- T10265- .

Note
Ensure that tensioning roller is seated correctly in rear toothed

belt guard -arrow-.
– Carefully turn eccentric of tensioning roller clockwise using

angle driver - T10264- . Indicator -2- must be roughly past the
centre of the gap in the base plate (corrects itself during pre‐
tensioning).
Ensure that nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten nut of ten‐
sioning roller.
Continued (all vehicles):
– Fit counterhold - T10172- as shown. Press counterhold -

T10172- in -direction of arrow- and keep camshaft pulley in
pretensioning position.
– In this position, first hand-tighten bolts -1- of camshaft pulley
wage
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and of toothed belt pulley for high pressure pump yand Vo then
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Tensioning roller B: aut or
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– Loosen tensioning roller nut -1-.

spec
– Carefully turn eccentric -2- of tensioning roller in anti-clock‐

t to the co
wise direction -arrow- using angle driver - T10409- . Indicator

-4- must be slightly past centre of gap in base plate -3- (recti‐
fies itself during pretensioning).
rrectne
Ensure that nut -1- does not turn as well.

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Markings on tensioning element and tensioning roller -arrow- are

now almost aligned.
– Hold tensioning roller in this position. Tighten tensioning roller
nut -1-.
– Fit counterhold - T10172- as shown. Press counterhold -

T10172- in -direction of arrow- and keep camshaft pulley in
pretensioning position.
– In this position, first hand-tighten new bolts -1- of camshaft

pulley and of toothed belt pulley for high-pressureapump
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Continuation for both tensioning rollers oris tee
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– Remove locking pin for diesel injection
ss pump - 3359- and ac
crankshaft stop - T10050- .
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– Turn crankshaft at least 2 rotations in engine direction of ro‐

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tation and set again to TDC no. 1 cylinder.

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belt pulley again.

h re
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spec
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– Now turn crankshaft in engine direction of rotation until crank‐

shaft stop pin -arrow- engages in sealing flange whilst turning.
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During the following checking procedure, only ise the camshaft and
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crankshaft must be secured in position. uItthois very difficult to find
r eo
the securing position of the high-pressure
ss a pump hub again. A mi‐ ra
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nor deviation -arrow-, though, does not influence engine opera‐
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– Check whether:
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♦ The hub can be fixed in place with the locking pin for diesel
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injection pump - 3359- .
hole
spec
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♦ Tensioning roller indicator is centred or maximum 5 mm to
t to the co
right of base plate notch.
If camshaft hub cannot be locked:
rrectness of i
– Pull crankshaft stop - T10050- back until pin uncovers hole.
l purpos
– Turn crankshaft out slightly past TDC by turning it in the op‐

posite direction of engine rotation.
nform
ercia
– Now turn crankshaft slowly in direction of engine rotation until

m
camshaft hub can be secured in position.
a
com
tion in
– After locking, loosen bolts of camshaft pulley.
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If pin of crankshaft stop - T10050- is standing on left next to hole:
do
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– Turn crankshaft in engine direction of rotation until crankshaft

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stop pin engages in sealing flange whilst turning. C py
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– Initially tighten securing bolts of camshaft toothed belt pulley
p by
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hand tight then tighten to specified torque. Prote
cted AG.
agen
If pin of crankshaft stop - T10050- is standing on right next to hole:

– Turn crankshaft slightly counter to engine direction of rotation
again.
– Turn crankshaft in engine direction of rotation until crankshaft
stop pin arrow engages in sealing flange whilst turning.
– Initially tighten securing bolts of camshaft toothed belt pulley
hand tight then tighten to specified torque.
Continuation:
– Remove locking pin for diesel injection pump - 3359- and
crankshaft stop - T10050- .
– Turn crankshaft at least 2 rotations in engine direction of ro‐
tation and set again to TDC no. 1 cylinder.
– Repeat measurement.
– If camshaft hub can be secured in position, tighten bolts as
follows:

AG. Volkswagen AG d
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California 2010 ➤ ut
h , Caravelle 2010 ➤ , Multivan 2010 ➤ , Transporter
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a
4-cylinder diesel
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s c
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♦ Camshaft sprocket: 45° further. Counterhold with counterhold
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- T10172- and adapters - T10172/4- .
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♦ High pressure pump sprocket: 90° further. Counterhold with
wit
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counterhold - T10172- and adapters - T10172/8- .
h re
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spec
– Install lower toothed belt guard.
es, in part or in w
t to the co
– Then install vibration damper/belt pulley.
– Install poly V-belt ⇒ page 49 .
rrectness of i
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– If present, install noise insulation ⇒ General body repairs, ex‐

t.
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terior; Rep. gr. 66 ; Noise insulation; Removing and installing C py
ht. rig
noise insulation . rig ht
py by
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Torque settings cted agen
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3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 135
⇒ “3.2 Measuring axial play of camshaft”, page 137
⇒ “3.3 Measuring radial play of camshaft”, page 138
⇒ “3.4 Removing and installing camshaft oil seal”, page 139
⇒ “3.5 Removing and installing camshaft”, page 140
⇒ “3.6 Checking hydraulic compensation elements”, page 148
⇒ “3.7 Removing and installing valve stem seals”, page 148
3.1 Assembly overview - valve gear
Note
♦ The plastic packing pieces for protecting

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♦ When cylinder head ishorrenewed,
is the coolant must be com‐ tee
pletely renewed ass awell.
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♦ Cylinder heads with cracks between the valve seats may be
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3. Valve gear 135

1 - Sealing ring
❑ Before installing, re‐
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3 - Bearing frame
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❑ Observe sequence for
loosing and tightening
⇒ page 137
rrectness of i
❑ Seal with silicone seal‐
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Catalogue (ETKA) .
4 - Exhaust camshaft
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❑ Note various versions
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❑ Exhaust camshaft with

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camshaft restraining
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wheel ⇒ page 137

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wheel ⇒ page 137 t. Cop py
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6 - Roller rocker fingers
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❑ Mark installation posi‐

tion
❑ Do not interchange
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
7 - Hydraulic compensation element
❑ Mark installation position
❑ Lubricate contact surfaces before installing.
8 - Valve
❑ Do not rework. Only lapping in is permitted.
❑ Mark installation position for re-installation.
❑ Valve dimensions ⇒ page 154
❑ Checking valve guides ⇒ page 153 .
9 - Cylinder head

10 - Valve stem seal

11 - Valve springs
12 - Valve spring plate
13 - Valve cotter
14 - Sealing cover
Retaining frame - specified torques and installation sequence

Releasing
– Unscrew bolts of support frame in sequence -24…1-.
Tightening sequence
1. First, tighten bolts of support frame hand-tight in sequence
-1….24-.
2. The, tighten bolts of support frame to 10 NM in the sequence
-1 … .24-.
Exhaust camshaft with camshaft restraining wheel
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Exhaust camshaft without camshaft restraining wheel

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3.2 Measuring axial play of camshaft

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3. Valve gear 137

♦ Universal dial gauge holder - VW 387-
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– Remove retaining frame ⇒ page 140 . um
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– Fasten dial gauge - VAS 6079- to cylinder head with universal
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dial gauge bracket - VW 387- as shown in the illustration. t. C rig
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– Press camshaft against dial gauge by hand.
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– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm.
3.3 Measuring radial play of camshaft

♦ Plastigage
– Remove roller rocker finger ⇒ page 140 .
– Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
• Plastigage must lie in the middle of the bearing.
– Fit retaining frame and tighten, ensuring that camshafts do not
turn.
– Remove retaining frame.

Radial clearance: 0.035 to 0.085 mm.

Torque setting
♦ ⇒ “3.1 Assembly overview - valve gear”, page 135
3.4 Removing and installing camshaft oil seal

equipment required
♦ Fitting tool - 10 - 203-
♦ Seal puller - 3240-
♦ Torque wrench - V.A.G AG. Volkswagen AG d
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♦ Bolt M12x1.5 x 65
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Removing
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 122 .
– Remove camshaft sprocket and hub ⇒ page 96 .
3. Valve gear 139

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– Insert thrust piece - 3240/1- into camshaft. aut or
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– Unscrew inner part of oil seal extractor - 3240- 2 turns (approx.

3 mm) from the outer part and lock in position with the knurled
screw.
nf
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– Lubricate threaded head of oil seal extractor, place it in posi‐
m
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tion and, exerting firm pressure, screw it into oil seal as far as
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– Loosen knurled screw and turn inner part against camshaft

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Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - 3240- onto camshaft as shown in illustration.

– Carefully slide oil seal -1- over guide sleeve onto camshaft.
– Carefully place seal onto camshaft.
– Press in oil seal with press piece of fitting tool - 10 - 203- and
bolt M12 × 1.5 x 65 as far as stop.
– Install camshaft sprocket and hub ⇒ page 96 .
– Install toothed belt and adjust the valve timing ⇒ page 122 .
Torque setting
3.5 Removing and installing camshaft


equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Puller - T10052-
♦ Camshaft fitting tool - lkswage es n
T40094- d byV
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♦ Camshaft fitting tool - utho
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T40095- ss
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♦ Camshaft fitting tool -

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3. Valve gear 141

♦ Silicone adhesive sealant ⇒ Electronic Parts Catalogue (ET‐

KA)
Removing
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 122 .
– Remove bolts -2- for camshaft pulley.
– Remove camshaft sprocket -1- from hub. agen
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– Counterhold hub with counterhold - T10051- and release hub
t to the co
bolt -1-.
– Unscrew hub bolt by turning it approx. 2 times.
rrectness o
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mer
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– Position puller - T10052- and align with hub holes. yi

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– Apply tension to hub by evenly tightening puller -2- until hub
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Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from camshaft taper.

– Remove vacuum pump ⇒ page 116 .

– Undo and remove bolt -2- from right exhaust gas recirculation
cooler -1-. gen AG
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– Undo and remove bolt -2- from left exhaust gas recirculation
cooler -1-.
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3. Valve gear 143

– Unscrew bolts of support frame in sequence -24…1-.

– Remove retaining frame.
– Carefully remove camshafts.
Installing
Note
Seal parting surface between retaining frame and cylinder head

using silicone adhesive sealant ⇒ Electronic Parts Catalogue
(ETKA) .
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The camshafts may be installed only withutthe
ho camshaft fitting
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tool - T40094- as described below. Otherwise
ss a the axial bear‐ ra
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ings in the retaining frame will be destroyed and the cylinder
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head must be replaced.
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– Remove sealant residue from cylinder block and retaining
wit
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frame using, for example, a plastic rotary brush.
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spec
es, in part or in w
Caution
t to the co
Make sure that no sealant residue gets into the cylinder head
or the bearings.
rrectness of i
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– Oil running surfaces of both camshafts.

m
Set up camshaft fitting tool - T40094- for camshafts as follows: at

om
ion
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– Remove supports -T40094/3- , -T40094/4- and -T40094/5-

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from base plate (screw connection from underneath).

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If the supports of the camshaft fitting tool - T40094- are not
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marked at present, the removed supports are to be marked, e.g.
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with number stamps, so they can be fitted in the original positions
later.

– Instead, attach supports -T40094/9- and -T40094/10- on outer

positions which have become free.
– Place support -T40094/2- in position “A” and support -
T40094/1- in position “F”.
– First insert inlet camshaft as shown. Ensure that indentation
-arrow- for cylinder head bolt faces »outwards«.
– Apply a 0.50 mm feeler gauge and push support -T40094/8-

into groove of inlet camshaft.
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– Now, insert exhaust camshaft d by V and lock in position by means
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– Position clamping tool
ss a - T40096/1- on exhaust camshaft c
gears.
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Ensure that the clamping jaw marked with an arrow is seated

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on the wider gear.

hole
spec
es, in part or in w
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– Tighten clamping tool - T40096/1- using knurled wheel so that

rrectness of i
faces of gear teeth are in alignment. Use a 13 mm open-jaw

l purpos
spanner to assist if necessary.

– Slide exhaust camshaft towards inlet camshaft until teeth en‐
nf
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– Position retaining frame on camshafts.

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• All camshaft bearings must be seated on the camshafts.

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3. Valve gear 145

– Set camshaft fitting tool - T40095- in place as illustrated in

order to hold camshafts in position in retaining frame.
– Remove cover - T40094/11- .
– Pull support - T40094/8- out of inlet camshaft groove.

2 mm).
– Apply sealant beads (approx. 2 ... 3 mm wide) -arrows- as
shown in diagram to clean sealing surfaces of cylinder head.
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The sealant beads must not be thickeraut than specified, otherwise
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– Install new cap ⇒ Item 14 (page 137) flush on cylinder head.

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– Take camshafts out of camshaft fitting tool - T40095- together

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with retaining frame and camshaft fitting tool - T40094- .

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– Carefully insert camshafts and retaining frame into cylinder

spec
head.
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– First tighten bolts of retaining frame hand-tight in sequence

-1…24-.
• The retaining frame should make contact with the cylinder
head over the complete surface.
– Tighten retaining frame bolts to final torque in the sequence
-1 … 24-.
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
– Renew camshaft seal ⇒ page 139 . . Volkswagen AG
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Further assembly is carried out in the reverse
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♦ After installing camshafts wait for approx. 30 minutes before
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starting engine. The hydraulic compensation elements must
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♦ After working on valve gear, carefully crank engine at least 2
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spec
revolutions by hand to ensure that no valves make contact on
starting.
t to the co
– Place hub onto camshaft.
rrectne
– Tighten bolt -1- of hub. Use counter-hold tool - T10051- to do
s
this.
s o
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mer
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– Push camshaft sprocket onto hub.
AG.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Hand-tighten new bolts -1- to camshaft sprocket so that there

is no play.
3. Valve gear 147

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– Fix hub in place with locking pin for diesel injection pump -
ce
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un
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3359- .
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– Install toothed belt and adjust valve timing ⇒ page 122 .
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– Install vacuum pump ⇒ page 116 .
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hole
– Install cylinder head cover ⇒ page 107 .
spec
es, in part or in w
Torque setting
t to the co
rrectness of i
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3.6 Checking hydraulic compensation ele‐
nform
ercia
ments
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♦ Feeler gauge
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♦ The hydraulic compensation elements cannot be repaired.
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♦ Irregular valve noise during starting is normal.
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2,500 rpm for 2 minutes (per‐
form road test if necessary).
– If the hydraulic compensation elements are still noisy, find out
which is the defective compensation element as follows:
– Turn crankshaft by the bolt for the toothed belt wheel until cam
of supporting element to be tested is facing upwards.
– Press roller rocker finger downwards -arrow- to check clear‐
ance between cam and roller rocker finger.
– If a 0.20 mm feeler gauge can be inserted between cam and
roller rocker finger, replace hydraulic compensation element
⇒ page 140 .
Torque setting
3.7 Removing and installing valve stem

seals

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Dismantling and assembling device for valve cotters - VAS

5161 A-
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– On vehicles with bi-turbo engine, remove connecting pipes

pe
ility
⇒ page 336 .
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– Remove glow plugs ⇒ page 502 .

hole
spec
– Remove camshafts ⇒ page 140 .

es, in part or in w
t to the co
– Place guide plate - VAS 5161/23- onto cylinder head.

– Secure guide plate on intake manifold side with knurled screw
rrectness of i
- VAS 5161/12- and tighten it hand-tight on studs using M6

collarless nuts -1-.
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– Screw sealing bolts - VAS 5161/10- into the guide plate.

– Screw adapter - VAS 5161/11- hand-tight into the relevant
glow plug thread.
– Insert punch - VAS 5161/3- in the guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Screw attachment fork - VAS 5161/5- with ratchet piece -

VAS 5161/6- into guide plate .
– Push spacer ring - VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter - VAS 5161/11- to compressed air supply,
using a standard commercially available union and apply pres‐ n AG. Volkswagen AG do
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• Minimum pressure: 6 bar. utho
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– Attach pressure fork - VAS 5161/2- to ratchet piece and spress
ce
le
assembly cartridge downwards.

un
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– At the same time, turn knurled screw of assembly cartridge
erm
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clockwise until tips engage in valve cotters.
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– Move knurled screw backwards and forwards slightly. This

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causes the valve cotters to be pressed apart and taken into
ole,
the assembly cartridge. spec

t to the co
– Release pressure fork.
– Remove assembly cartridge with spacer ring, valve plate and
valve spring.
rrectne
– Pull off valve stem seals using valve stem seal puller - 3364- .
ss o
cial p
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mer
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Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to

new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer to tap lightly on fitting
tool until valve stem oil seal is fitted to stop.
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– Remove plastic sleeve. edb ara
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– Insert valve spring and valve ho eo
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– If valve cotters have been removed from assembly cartridge ,

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they need to be put into insertion device - VAS 5161/18- first.

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Larger diameter of valve cotters faces upwards.
es, in part or in w
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– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
rrectness of i
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nform
mercia
a
com
tion in
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3. Valve gear 151

– Insert assembly cartridge - VAS 5161/8- into guide plate again.

– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This action will
install the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
Assemble in reverse order of dismantling. During this step, ob‐
serve the following:
– Install glow plugs ⇒ page 502 .
– Install camshafts ⇒ page 140 .
AG. Volkswagen AG d
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Note rised
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♦ Engine is not to be rotated for approx. 30 minutes after instal‐
ss c
ce
le
ling camshafts. The hydraulic compensation elements must

un
pt
settle (otherwise valves will strike pistons).
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♦ After working on the valve gear, turn the engine carefully at
ility
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least 2 rotations to ensure that none of the valves make con‐
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h re
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Torque setting
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♦ ⇒ “1.1.2 Assembly overview - turbocharger, bi-turbo”,

page 278
ss o
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mer
atio
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4 Inlet and exhaust valves

⇒ “4.1 Reworking valve seats”, page 153
⇒ “4.2 Checking valve guides”, page 153
⇒ “4.3 Valve dimensions”, page 154
4.1 Reworking valve seats
Note
Valve seats must not be reworked due to the very small toleran‐
ces.
4.2 Checking valve guides

gen AG
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♦ Universal dial gauge holder - VW d387-
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Test sequence
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Prote AG.
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine rock. Wear limit: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
4. Inlet and exhaust valves 153

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4.3 Valve dimensions
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Note
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Valves must not be reworked. Only lapping-in is permitted.
es, in part or in w
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Dimension Inlet valve Outlet valve
rrectness of i
∅a mm 26.60 26.00
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∅b mm 5.940 5.940
c mm 99.30 99.10
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α ∠° 45 45
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17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 155
⇒ “1.1.2 Assembly overview - sump/oil pump, vehicles with bal‐
ancer shaft module”, page 158
⇒ “1.2 Removing and installing oil pan”, page 160
⇒ “1.3 Removing and installing oil pump”, page 163
⇒ “1.4 Engine oil:”, page 165
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 166
1.1 Assembly overview - sump/oil pump

⇒ “1.1.1 Assembly overview - sump, oil pump, vehicles without
⇒ “1.1.2 Assembly overview - sump/oil pump, vehicles with bal‐
ancer shaft module”, page 158
1.1.1 Assembly overview - sump, oil pump, vehicles without balance shaft module
1 - Bolt AG. Volkswagen AG d

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❑ 15 Nm olksw not
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❑ With seal ss a c
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❑ Must sit on dowel

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⇒ page 57
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❑ Insert with silicone seal‐
h re
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spec
Catalogue (ETKA) .
t to the co
❑ Before installing, re‐ rrectne
move oil residue from
s
crankshaft journal using

s o
a clean cloth.
cial p
f inform
❑ Renewing crankshaft oil

mer
seal on belt pulley end

atio
m
⇒ page 55 .
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3 - Toothed belt for oil pump

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❑ Check for damage and

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❑ Replace if necessary . Cop py
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Prote AG.
♦ Belts which have been in use
longer can sag.
♦ This is not a fault and does not
necessarily mean belt needs re‐
placing.
1. Sump, oil pump 155

4 - Bolt
❑ 10 Nm
5 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 165 .
6 - Guide tube
❑ Renew O-ring after each removal
7 - Fastener
8 - Dowel sleeves
9 - O-ring
10 - Bolt
❑ 10 Nm
11 - Oil pump with pressed-on toothed belt pulley
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
If toothed belt or oil pump have to be removed:
Note
♦ Check oil pump for ease of

movement.
♦ It should be possible to turn
toothed belt sprocket easily with
1 finger.
♦ Replace if difficult to turn. AG. Volkswagen AG d
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12 - Intake manifold orise nte
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❑ Clean strainer if soiled. ss a ra
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13 - Baffle plate
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14 - Bolt
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❑ 15 Nm
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15 - Bolt
h re
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❑ Specified torque and tightening sequence ⇒ page 157

spec
t to the co
16 - Oil pan
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
rrectne

ss
17 - Bolt
o
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❑ 15 Nm
nform
mer
18 - Sealing ring
atio
om

n
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19 - Oil drain plug

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❑ 30 Nm
t.
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20 - Bolt ht. rig
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❑ 10 Nm
co Vo
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156 Rep. gr.17 - Lubrication

21 - Oil level and oil temperature sender - G266-

22 - Sealing ring
23 - Wiring harness for oil level and oil temperature sender - G266-
24 - Bolt
❑ 27 Nm
25 - Oil spray jet
Sump - specified torque and tightening sequence
Note
– Tighten bolts in 3 stages:

stage Bolts Torque setting
1. -1 to 20- In diagonal sequence to 5 Nm
2. -Arrows- 40 Nm
3. -1 to 20- diagonally in stages; final torque
13 Nm
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157
Prote AG.
1. Sump, oil pump
1.1.2 Assembly overview - sump/oil pump, vehicles with balancer shaft module
1 - Oil pan
⇒ page 160
❑ Specified torque and
tightening sequence
⇒ page 160
2 - Bolt agen
AG. Volkswagen AG d
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❑ 10 Nm by
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3 - Suction hose ut
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4 - Bolt
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❑ 10 Nm
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5 - O-ring
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hole
spec
6 - Oil pump
es, in part or in w
t to the co
⇒ page 163
❑ Before installing, check
rrectness of i
that both dowel sleeves
for centring oil pump on
l purpos
balance shaft module

are fitted.
nform
ercia
7 - Drive shaft for oil pump

m
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8 - Locking ring
on in
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❑ Must lie in base of
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10 - Bolt by c lksw
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Prote AG.
❑ 20 Nm + 90°
11 - Hub
❑ For intermediate gear wheel.
12 - Bolt
❑ 90 Nm + 90°
13 - Thrust washer
❑ Note installation position ⇒ page 160 .
14 - Intermediate gear
❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
wear.

Caution
When installing the inter‐
mediate gear wheel, en‐
sure that the thrust
washer is seated cor‐
rectly ⇒ page 160 .
❑ Installation position: part number must be visible.

❑ Installing ⇒ page 181
15 - Thrust washer
❑ If necessary, attach to housing with grease when installing intermediate gear wheel
16 - Spur gear for crankshaft
❑ Renew if signs of wear are found ⇒ page 78
17 - Balancer shaft module
❑ Removing ⇒ page 181
❑ Installing new balancer shaft module ⇒ page 181 .
❑ Reinstalling previously run balancer shaft module ⇒ page 181 .
❑ Before installing, check that the two dowel sleeves for centring balance shaft module on cylinder block
are fitted.
18 - Bolt
AG. Volkswagen AG d
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❑ Note tightening
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balancer
utho shaft module ⇒ page 181 . eo
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❑ M7 s = 13 Nm + 90°
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❑ M8 = 20 Nm + 90°
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19 - Oil extraction pipe

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20 - Bolt
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❑ 10 Nm
hole
spec
21 - Bolt
es, in part or in w
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❑ 40 Nm
22 - Bolt
rrectness of i
❑ 45 Nm
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23 - Bolt
❑ Tighten in stages and in diagonal sequence.
nf
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❑ 15 Nm
orm
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24 - Sealing ring
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25 - Oil drain plug

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Thrust washer installation position
Caution
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When installing intermediate
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or and subsequently seize. If necessary,ntfix
ise
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place with agrease
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on balancer shaft module. or
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Sump - specified torque and tightening sequence
h re
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spec
– Renew bolts for oil sump.
es, in part or in w
t to the co
– Tighten bolts in diagonal sequence in 3 stages as follows:
1. Tighten bolts -1 … 20- in diagonal sequence initially to 5 Nm.
rrectness of i
2. Tighten bolts -arrows- of sump-to-gearbox connection to
l purpos
40 Nm.
3. Tighten bolts -1 … 20- in diagonal sequence to 15 Nm.
nform
mercia
at
om
ion
c
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or
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1.2 Removing and installing oil pan

at
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priv
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Cop py
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au 2010 ➤ , Multivan 2010 ➤ , Transporter 20 ...or a
th
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nl
pt
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equipment required
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♦ T-bar and socket, 10 mm -
wit
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3185-
h re
hole
spec
♦ Hexagon bit, long reach -
es, in part or in w
T10058-
t to the co
1331-
rrectness of i
♦ Used oil collector and ex‐
l purpos
tractor - V.A.G 1782-
nform
mercia
at
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ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
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by
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Prote AG.
Removing
noise insulation .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine and drain engine oil.
– Unscrew nut -5- and push coolant circulation pump 2 - V178-
-1- aside - coolant hoses and connectors remain attached.

– Pull connectors -arrow- off oil level and oil temperature sender
- G266- .
– On vehicles with bi-turbo engine and four-wheel drive, the

bevel box must be removed and the gearbox must be detach‐
ed from the engine.
– Remove connecting bolts for sump and gearbox.
Note
On vehicles with bi-turbo engine and manual gearbox from model

year 2010, it may not be possible to unscrew bolts -12- and -13-
depending on the type of dual mass flywheel installed.
– If necessary, remove flywheel ⇒ page 62 .

– Unscrew bolts of oil sump in diagonal sequence.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
olkswagen AG
en AG. V
– Remove sealant remaining on crankcase with
olksflat scraper.
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Wear protective goggles.

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– Remove sealant residue on oil sump using a rotary brush, e.g.

wit
is n
with a hand drill with a plastic brush attachment.

h re
ole,
spec

t to the co
Installing
rrectne
Note
ss o
cial p
f in
♦ Observe use-by-date of sealant.

form
mer
♦ The sump must be installed within 5 minutes of applying sili‐

atio
m
cone sealing compound.

o
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c
i
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n thi
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♦ The sealant bead must not be thicker. Otherwise, excess seal‐

t
sd
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ant may enter the sump and block the strainer in the suction
i
o
pr
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line of the oil pump.

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Prote AG.


3 mm).
– Apply silicone sealant to clean sealing surface of sump as
shown. Sealant bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump. (The figure shows the position of
the sealant bead on the crankcase).
– Place oil sump in position and slightly tighten the sump--to-
gearbox connecting bolts and all the oil sump bolts. Ensure
that sump is flush against intermediate plate and gearbox
flange.
Note
♦ When installing sump with engine out of vehicle, ensure that

sump is flush with cylinder block at flywheel end.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Install oil pan. AG. Volkswagen AG d

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Torque settings olksw not
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♦ ⇒ “1.1.1 Assembly overview - sump, oil pump, tvehicles
ho
ri without eo
balance shaft module”, page 155 s au ra
c
s
ce
le
♦ ⇒ “1.1.2 Assembly overview - sump/oil pump, vehicles with

un
pt
balancer shaft module”, page 158
an
d
itte
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erm
ab
♦ Noise insulation; Assembly overview - noise insulation ⇒
ility
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wit
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Removing and installing noise insulation

h re
ole,
spec
t to the co
Bolts for oil level and oil tem‐ 10 Nm

perature sender - G266-
rrectne
1.3 Removing and installing oil pump

ss
⇒ “1.3.1 Removing and installing oil pump, vehicles without bal‐

o
cial p
ance shaft module”, page 163

inform
mer
⇒ “1.3.2 Removing and installing oil pump, vehicles with balancer

atio
m
shaft module”, page 164

o
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i
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1.3.1 Removing and installing oil pump, vehi‐

thi
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sd
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cles without balance shaft module

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Removing
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Cop py
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– Remove oil pan ⇒ page 160 . gh ht
pyri by
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Prote AG.

– When oil pump is to be renewed, unscrew bolts -4- and remove

oil intake pipe -3-.
– Unscrew bolts -arrows- and remove baffle -2-.
– Detach oil pump -1- from toothed belt and remove pump.
Installing
Note
Renew O-ring between oil pump and oil intake pipe.
– Insert new dowel sleeves when oil pump has no dowel sleeves
-arrows- for centring oil pump.
– Check oil pump for ease of movement, turn toothed belt pulley
with one finger for this.
Note
♦ If oil pump does not move easily, it must be renewed.

♦ A damaged toothed belt must be renewed.
♦ The toothed belt can sag after long use, this is not a fault.
– Check toothed belt for oil pump.

– Fit oil pump with toothed belt pulley into toothed belt and tight‐
en along with baffle.
– Replenish engine oil and check oil level ⇒ page 165 .
AG. Volkswagen AG d
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♦ ⇒ “1.1.1 Assembly overview - sump, oil pump, vehicles without rise
d
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balance shaft module”, page 155 utho eo
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s a c
s
♦ Noise insulation; Assembly overview - noise insulation ⇒ ce
e
nl
General body repairs, exterior; Rep. gr. 66 ; Noise insulation; pt

du
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itte
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erm
ab
ility
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1.3.2 Removing and installing oil pump, vehi‐

wit
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cles with balancer shaft module

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spec
es, in part or in w
Removing
t to the co

rrectness of i
Caution
l purpos
Bolt on intermediate gear wheel must not be loosened.

nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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co lksw
by
cted agen
164
Prote AG.
Rep. gr.17 - Lubrication
– Remove circlip -1- with circlip pliers.

– Use a commercially available magnet to pull drive shaft -2- out
of oil pump -arrow-.
– Unscrew bolt -4- and detach suction line from oil pump.
– Remove bolts -3- and -5- and remove oil pump.
Installing
Note
♦ Renew O-ring.
AG. Volkswagen AG d
♦ Renew damaged or over-tensioned circlip. olksw
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♦ The retaining ring must seat in the base of therigroove.
se
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– Ensure both dowel sleeves are in place before
s installing oil
ce
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pump.
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Torque settings
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nf
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1.4 Engine oil:
atio
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n in
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Markings on oil dipstick
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The oil level may be in area -d- due to the infiltration of fuel in the
t. rig
gh ht
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engine oil as a result of unfavourable driving conditions after fill‐ cop Vo
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ing. This is a perfectly normal and self-regulating characteristic. cted agen
Prote AG.
It is not necessary to adjust the engine oil level.
1 - Min. mark
2 - Max. mark
a - Oil level in min. mark area: replenish engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.

l wage
kscommon rail) - Edition 08.2016
es n
Vo ot gu
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ris
1.5 Removing and installing oil level and oil au
tho eo
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temperature sender - G266-
ss c
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un
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Removing
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ab
– Drain engine oil.
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– Unscrew bolts -1- and remove oil level and oil temperature
spec
sender - G266- -item 4-.
t to the co
Installing
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– Replace self-locking bolts -1- and seal -2-.
ss
– Replenish engine oil and check oil level ⇒ page 165 .
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Torque settings
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perature sender - G266- cted agen
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2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 167
⇒ “2.2 Removing and installing oil filter housing with engine oil
cooler single turbo engine ”, page 169
⇒ “2.3 Removing and installing engine oil cooler”, page 171
⇒ “2.4 Checking engine oil cooler for leaks”, page 174
2.1 Assembly overview - engine oil cooler

⇒ “2.1.1 Assembly overview - oil filter housing with engine oil
cooler, single turbo engine ”, page 167
⇒ “2.1.2 Assembly overview - oil filter with engine oil cooler, bi-
turbo engine ”, page 169
2.1.1 Assembly overview - oil filter housing

with engine oil cooler, “single turbo en‐
gine” lksw
agen
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Caution tho or
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Seals 11 and 14 must not be lubricated with oil. The coolant
ce
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pt
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seals would otherwise swell up.
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erm
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es, in part or in w
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mercia
at
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c
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ate
do
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for
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2. Engine oil cooler 167

AG. Volkswagen AG d
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California 2010by➤ V , Caravelle 2010 ➤ , Multivan
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d
4-cylinder odiesel
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tee 08.2016
h
aut or
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1- O-ring ss
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2 - Sealing cover
erm
ab
ility
ot p
❑ 25 Nm
wit
is n
h re
3 - O-ring
ole,
spec
t to the co
4 - O-ring
rrectne
5 - Oil filter element
6 - Guide tube
ss o
❑ Renew O-ring after
cial p
f in
each removal
form
mer
7 - Bolt
atio
om
n
❑ 10 Nm
c
i
or
n thi
te
sd
8 - Fastener
iva
o
pr
cum
r
9 - Engine oil cooler

fo
en
ng
t.
yi
❑ Ensure clearance to ad‐
Co
Cop py
jacent components.
t. rig
gh ht
yri by
❑ Checking engine oil
op Vo
by c lksw
cted
cooler for leaks
agen
Prote AG.
⇒ page 174
10 - Bolt
❑ Initial specified torque:
5 Nm
❑ 11 Nm
11 - Rubber seals
❑ May not be lubricated
with oil
❑ Fit into lugs on engine oil cooler.
12 - Bolt
❑ First, fit upper left and lower right bolts in place. Then, tighten all 4 bolts alternately in diagonal sequence .
❑ 14 Nm +180°
13 - Oil filter bracket
❑ Ensure clearance to adjacent components.
14 - Rubber seals
❑ May not be lubricated with oil
❑ Fit into lugs on oil filter bracket.

2.1.2 Assembly overview - oil filter with engine

oil cooler, “bi-turbo engine”
Note
On “bi-turbo engines” the oil filter and engine oil cooler are se‐
cured to the exhaust gas recirculation cooler
⇒ “3.1.1 Assembly overview - exhaust gas recirculation cooler, bi-
turbo engine ”, page 482 .
2.2 Removing and installing oil filter housing with engine oil cooler “single turbo
engine”

equipment required
♦ Release lever - 80 - 200-
1410-
♦ Used oil collector and ex‐
tractor - V.A.G 1782-
VAS 6362-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
Removing agen oes
olksw not
V gu
by a
– Remove oil filter relement
ised
-3- ⇒ Maintenance ; Booklet 19ra.nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
– Pull oil dipstick -3- out slightly and remove screw -4-.
his
ate
do
riv

p
cum
for
en
g
– Remove continued coolant circulation pump - V51-

n
t.
yi Co
op
⇒ page 226 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Push clip -3- off guide tube -1- for oil dipstick with removal lever
- 80 - 200- .
– Pull oil dipstick guide tube -1- off cylinder block upwards and
push to side.

– Remove coolant hose -3-. To do this, release hose clip -2-.

– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -1- and remove oil filter bracket with engine oil
cooler.
– Clean soiled places thoroughly.
Installing
Note
♦ Renew gaskets, seals and O-rings.

♦ Hose unions and air intake pipes and hoses must be free of
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ EKTA (Electronic Parts Cata‐
logue) .
– Bolt on oil filter bracket hand-tight in the sequence -1 … 4-.

– Tighten bolts in the sequence -1 … 4-.
– Install dipstick guide tube ⇒ page 167 .
olkswagen AG
en AG. V
– Install oil filter element,
olks replenish engine oil and
wag does
nocheck oil level
t gu
⇒ Maintenance ed
by;VBooklet 19 . ara
ris nte
– Replenish thocoolant in cooling system, change coolant if engine
eo
au ra
oil cooler
ss has been renewed ⇒ page 187 . c
ce
le
un
pt
Torque settings
an
d
itte
y li
♦ ⇒ “2.1.1 Assembly overview - oil filter housing with engine oil

rm
ab
pe
ility

ot
wit
, is n
Or
h re
hole
spec
♦ ⇒ “2.1.2 Assembly overview - oil filter with engine oil cooler,

es, in part or in w
bi-turbo engine ”, page 169

t to the co
rrectness of i
2.3 Removing and installing engine oil cool‐

l purpos
er
nform
ercia

m
a
com
tio
♦ Used oil collection and extraction unit - V.A.G 1782-

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Drip tray for workshop hoist - VAS 6208-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Spring-type clip pliers - VAS 6362-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Removing t. Cop py
rig
gh ht
– Drain coolant ⇒ page 187 . pyri by
Vo
o
by c lksw
cted agen
– Remove continued coolant circulation pump - V51- Prote AG.
⇒ page 226 .
– In addition to draining coolant from engine, pull coolant hose
from oil filter holder -arrow-.

– Remove oil filter element.
– Unscrew bolts -arrows-.

– Remove engine oil cooler from housing.
Installing
Install in reverse order of removal. During this step, observe the
following:
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
♦ Renew gaskets, seals and O-rings. ut
ho eo
ra
s a c
♦ Hose unions and air intake pipes and hoses must be free of s
ce
e

nl
pt
du
an
itte
y li
♦ Secure all hose connections with the hose clips corresponding
erm
ab
to original equipment ⇒ ETKA (Electronic Parts Catalogue) .
ility
ot p
wit
, is n
h re
hole
– Insert new seals into oil-free lugs -arrow- on oil filter bracket. spec
es, in part or in w
– Carefully slide engine oil cooler onto centring pins.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Press oil cooler on until it is flush -1- with end of centring pins.
– Start new bolts, and screw them in until heads make contact.
– Tighten bolts -arrows- alternately in diagonal sequence in 3

steps.
– Install oil filter element, replenish engine oil and check oil level
⇒ page 165 .
– Replenish coolant in cooling system, change coolant if engine
oil cooler has been renewed ⇒ page 187 .
Torque settings
AG. Volkswagen AG d
agen oes
ksw
2.4 Checking engine oil cooler for leaks
d by
Vol not
gu
ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen
♦ Refractometer - T10007 A- olksw
oes
not
byV gu
ara
d
♦ Hose clamps to 25 mm - orise nte
eo
3094- aut
h
ra
ss c
♦ Cooling system tester -
ce
e
nl
pt
V.A.G 1274-
du
an
itte
y li
erm
♦ Adapter for cooling system
ab
ility
tester - V.A.G 1274/8-
ot p
wit
, is n
♦ Pliers for spring-type clips -
h re
hole
VAS 5024 A-
spec
es, in part or in w
♦ Drip tray - V.A.G 1306- or
t to the co
drip tray for workshop hoist
- VAS 6208-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Without illustration:
♦ Expansion tank
♦ Commercially available plug
♦ Commercially available cap
♦ Commercially available coolant hose
Condition:
• Engine cold
Test sequence
noise insulation .
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024 A- .
– Remove engine oil cooler with housing ⇒ page 169 .

Note
olkswagen AG
en AG. V
♦ Collect escaping coolant
olks with drip tray for workshop
wag does
no hoists -
VAS 6208- . db
yV t gu
ara
rise nte
♦ Collect leaking
au
tho engine oil with an absorbent cleaning cloth, e o if
ra
necessary.
ss c
ce
e
nl
pt
du
an
Checking when removed
itte
y li
erm
ab
– Clamp the casing with the old gasket onto a suitable, flat clean
ility
ot p
surface with the help of a bar clamp -4-.
wit
, is n
h re
– Attach plug -2- to venting connection of expansion tank -1-.
hole
spec
es, in part or in w
– Attach coolant hose -3- to engine oil cooler -5- and to expan‐
t to the co
sion tank -1-.
– Fill expansion tank up to max. mark.
rrectness of i
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on coolant expansion tank -1-.
l purpos
– Generate about 1.6 bar pressure using hand pump of tester.
nf
ercia
o
– Observe pressure drop on pressure gauge. A pressure drop
rm
m
within 10 minutes is not permitted.

atio
om
n in
c
If the pressure drops:

or
thi
te
sd
a
– Renew engine oil cooler ⇒ page 171 .

iv
o
r
rp
cu
o
Install in reverse order of removal. During this step, observe the

f
en
ng
t.
following:
yi Co
Cop py
ht. rig
– Renew housing seal. rig ht
py by
co Vo
by lksw
– Check coolant level and, if necessary, replenish Prote
cted AG.
agen
⇒ page 187 .
– Check engine oil level and, if necessary, replenish
⇒ page 165 .
Torque settings

3 Oil filter, oil pressure switch

⇒ “3.1 Removing and installing oil pressure switch F1 ”,
page 177 en AG. V
olkswagen AG
ag does
ksw not
Vol
⇒ “3.2 Checking oil pressure”,
by page 178 d
gu
ara
ise nte
⇒ “3.3 Measuring oil uconsumption”,
tho
r
page 180 eo
a ra
ss c
3.1 Removing and installing oil pressure
ce
e
nl
pt
du
switch - F1-
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
Removing
at
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
♦ Oil pressure switch - F1- is installed inaccessibly on rear left p by
co Vo
of cylinder head.
by lksw
cted agen
Prote AG.
♦ Removal and installation must be carried out from right-hand
side, behind cylinder head.
– Pull back heat shield -arrow-.
3. Oil filter, oil pressure switch 177


– Unscrew bolt -2- and remove lifting eye -1-.

– Release connector -4- and pull off.
– Unscrew oil pressure switch - F1- -3-.
Installing
Torque settings
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
3.2 Checking oil pressure thorise nte
eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
♦ Oil pressure tester - V.A.G
1342-
AG. Volkswagen AG d
♦ Voltage tester - V.A.G 1527 agen oes
olksw not
B- byV gu
ara
ed
ris nte
o
♦ Adapter set - V.A.G 1594 aut
h eo
ra
C- ss c
ce
le
un
pt
♦ Current flow diagram
an
d
itte
⇒ Current flow diagrams,
y li
rm
ab
Electrical fault finding and
pe
ility
Fitting locations
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Checking oil pressure switch - F1-

Test conditions
• Oil level OK, checking ⇒ page 165
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Test sequence
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Pull connector off oil pressure switch - F1- .
3. Oil filter, oil pressure switch 179

swage es n
– Remove oil pressure switch - F1- -2- and screw into oil pres‐ by Vo lk ot g
ua
sure tester - V.A.G 1342- . ir se
d ran
tee
tho
or
– Screw tester into oil filter bracket in place of oil pressure
ss
au ac
switch .
ce
le
un
pt
an
– Connect brown wire -1- of tester to earth (-).
d
itte
y li
erm
ab
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
ility
ot p
and oil pressure switch using cables from auxiliary test set -
wit
is n
V.A.G 1594 C- .
h re
ole,
spec
• LED must not light up.
t to the co
If the LED lights up:
– Replace oil pressure switch - F1-
rrectne
If LED does not light up:
– Start engine and increase revolutions slowly.
ss o
cial p
f
• From 0.30 to 0.60 bar the LED must light up, otherwise renew
inform
oil pressure switch - F1- .
mer
atio
Checking oil pressure
om
n
c
i
or
n
Condition
thi
te
sd
va
• Oil pressure tester - V.A.G 1342- is connected.

i
o
pr
cum
r
fo
en
ng
Test sequence
t.
yi Co
Cop py
– Increase engine speed further.
t. rig
gh ht
pyri by
Vo
o
• Oil pressure at idling speed: at least 0.6 bar
c by lksw
cted agen
Prote AG.
• Minimum oil pressure at 2,000 rpm: at least 1.5 bar
• At 2000 rpm and oil temperature of 80 °C, oil pressure should
be at least 1.0 bar.
• At higher engine speeds, the oil pressure must not exceed 5.0
bar.
If specification is not attained:
– Renew oil pump if necessary ⇒ page 163 .
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
3.3 Measuring oil consumption

– Apply handbrake.
– Manual gearbox: gear lever in neutral.
– Automatic gearbox: move selector lever to position “N”.
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Carry out program “oil consumption measurement” using
⇒ Vehicle diagnostic tester.

4 Balancer shaft module

⇒ “4.1 Removing and installing balance shaft module”,
page 181 AG. Volkswagen AG d
agen o es n
lksw
4.1 Removing and installinged bbalance
yV
o
shaft module ot g
ua
ran
ris tee
ho
aut or
ac
Special tools and workshop ss
ce
e
equipment required
nl
pt
du
an
♦ Bits - T10099- itte
y li
erm
ab
ility
♦ Locking device - T10255-
ot p
wit
, is n
♦ 14 mm tool insert - T10393-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Crankshaft stop - T10050- for engines with round crankshaft

pulley
4. Balancer shaft module 181

Removing
– Rotate crankshaft to TDC and lock in position with crankshaft
stop - T10050- .
Note
The markings on the crankshaft pulley -2- and the crankshaft stop
- T10050- -1- must align. At the same time, the pin of the crank‐
shaft stop - T10050- must engage in the drilling in the sealing
flange.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
182
agen
Prote AG.
Rep. gr.17 - Lubrication
– Unscrew bolts in sequence -8 to 1- and remove balance shaft

module together with oil pump. gen AG
. Volkswagen AG
d wa oes
olks not
Installing a new balancer shaft module: byV gu
ara
ed nte
ris
Procedure: tho eo
au ra
c
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ The spur gear drive of the balancer shaft module must be in‐
ility
ot p
stalled with correct tooth backlash.
wit
, is n
h re
♦ A coating is applied to the new intermediate gear wheel to set
hole
spec
the correct tooth backlash.
es, in part or in w
t to the co
♦ Intermediate gear wheels that have a white point are partly
coated around the circumference. Intermediate gear wheels
without a white spot are fully coated around the circumference
rrectness of i
♦ The coating wears off after a short time. This thereby sets the
l purpos
tooth backlash.
♦ For this reason a new balancer shaft module must always be
nform
ercia
installed with a new intermediate gear wheel with special coat‐

ing.
m
at
om
ion
♦ A white spot is positioned only on partly coated intermediate
c
in t
or
gear wheel to ensure correct installation position.
his
ate
do
riv
♦ For intermediate gear wheels with coating around the com‐

p
cum
or
plete circumference the installation position is not relevant.

f
en
ng
t.
yi Co
op
♦ Bolts that are firmly tightened at a specified angle must be C py
t. rig
renewed.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
• Crankshaft locked in position with crankshaft stop - T10050- .
AG.
Caution
The threaded connection of the intermediate gear wheel must

be loosened to position the balancer shaft module. When doing
this, do not loosen the bolt fully to prevent that the thrust wash‐
er does not slip behind the intermediate gear wheel. Thrust
washer installation position ⇒ page 160
Note
For illustration purposes the following procedure is described with

sealing flange removed.
– Before positioning balancer shaft module on cylinder block,

loosen bolt -1- for intermediate gear wheel approx. 45°.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balance shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
Note
Take care not to damage coating on intermediate gear wheel.

AG. Volkswagen A
California 2010 ➤ agen
ks,wCaravelle 2010 ➤ , Multivan 2010 ➤ , Transporter 20 ...
G do
es n
Vol ot g
4-cylinder diesel
ed by engine (2.0 l engine, common rail)
ua - Edition 08.2016
ra
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tho eo
– Fit bolts insssequence
au
-1 to 8- and hand-tighten at first. ra
c
ce
le
– Tighten bolts of balancer shaft module as follows:
un
pt
an
d
itte
y li
1. Initially tighten bolts in the sequence -1 … 8- to 6 Nm.
erm
ab
ility
ot p
2. Tighten bolts -5- and -7- to 13 Nm.
wit
is n
h re
3. Turn bolts -5- and -7- 90° further with rigid spanner.
ole,
spec
4. Tighten bolts -1 … 4-, -6- and -8- to 20 Nm.
t to the co
5. Turn bolts -1 to 4-, -6- and -8- 90° further with rigid spanner.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Lock balancer shaft with locking device - T10255- . To do this,

i
o
pr
cum
r
turn balancer shaft if necessary.

fo
en
ng
t.
yi Co
• Locking tool pin must engage in groove in balancer shaft when Cop py
t. rig
doing this. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
– Carefully fit gear wheel of balancer shaft onto balancer shaft.

While doing this, press intermediate gear a little to one side.
Note
♦ Ensure threaded holes in balancer shaft are central within

elongated holes of balancer shaft gear wheel.
♦ If elongated holes in balancer shaft gear wheel cannot be
aligned with the threaded holes, the balancer shaft gear wheel
must be turned further by a corresponding number of teeth and
must be mounted again.
– Securely tighten balancer shaft gear wheel -arrows-.

– Remove locking tool - T10255- .

The following 3 procedures must be performed simultaneously

(2nd mechanic required):
– Press intermediate gear -3- forcefully (with assistance of a
wooden rod if necessary) in -direction of arrow- into teeth of
drive gear wheel -2- and balancer shaft gear wheel -1- so that
they mesh.
– When doing so, turn the balancer shaft gear wheel -1- slightly
in an anticlockwise direction. wagen AG. Volkswagen AG does
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Vol gu
– Firmly tighten bolt for intermediate
ed
by gear wheel using bit - ara
nte
T10099- and 14 mm thotool
ris insert - T10393- eo
⇒ Item 12 (page 158)
sa
u . ra
c
s
ce
e
– Remove crankshaft stop - T10050- .

nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
No backlash may be perceptible after installing intermediate gear
hole
spec
wheel. This can be checked by hand using light force.
es, in part or in w
t to the co
rrectness of i
l purpos
– Install vibration damper/belt pulley (replace bolts) ⇒ page 45 .

nform
ercia
Torque settings
m
at
om
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n
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in t
or
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e

at
do
riv

p
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for
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Cop py
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Re-installing a previously used balancer shaft module:
AG.
Caution
If the bolt for the intermediate wheel has been removed, a new
intermediate wheel with coating must be installed and the hub
⇒ Item 11 (page 158) including bolt ⇒ Item 12 (page 158) and
thrust washer must be renewed. This also applies to replace‐
ment of the drive gear wheel on the crankshaft and to removal
of the crankshaft. Otherwise, the tooth backlash will be incor‐
rect. Procedure when installing ⇒ page 78 .

Note
♦ If the previously used balancer shaft module is to be reinstalled

and neither has the drive gear wheel on crankshaft been re‐
newed nor has the crankshaft been removed, proceed as
follows. The intermediate gear wheel must also not have been
loosened.
♦ If a further tightening angle is specified for certain bolts, these
must be renewed.
lkswage es n
o ot g
yV
– Lock balancer shaft with locking deviceis-edT10255- . To do this,
b ua
ran
turn balancer shaft if necessary. thor tee
or
au ac
s
• Locking tool pin must engage in groove in balancer shaft when
s
ce
le
doing this.
un
pt
an
d
itte
y li
– Check to see whether both dowel sleeves are in place to cor‐
erm
ab
rectly position balance shaft module on cylinder block.
ility
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wit
– Place balancer shaft module on cylinder block.
is n
h re
ole,
• The intermediate gear wheel must mesh in the crankshaft
spec
drive gear wheel when the balancer shaft is locked.
t to the co
• The intermediate gear wheel must have a slight tooth back‐
lash.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
– Fit bolts in sequence -1 to 8- and hand-tighten at first.
or
n thi
te
sd
va
– Tighten bolts of balancer shaft module as follows:

i
o
pr
cum
r
fo
1. Initially tighten bolts in the sequence -1 … 8- to 6 Nm.

en
ng
t.
yi Co
op
2. Tighten bolts -5- and -7- to 13 Nm.
C py
t. rig
gh ht
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3. Turn bolts -5- and -7- 90° further with rigid spanner.
cop Vo
by lksw
cted agen
Prote AG.
4. Tighten bolts -1 … 4-, -6- and -8- to 20 Nm.
5. Turn bolts -1 to 4-, -6- and -8- 90° further with rigid spanner.
– Remove crankshaft stop - T10050- .
– Install vibration damper/belt pulley (replace bolts) ⇒ page 45 .
Torque settings

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Draining and adding coolant”, page 187
⇒ “1.2 Checking cooling system for leaks”, page 192
⇒ “1.3 Assembly overview - coolant hoses”, page 193
⇒ “1.4 Connection diagram for coolant hoses - vehicles
AG. with basic
Volkswagen AG
agen does
equipment”, page 195 Volksw not
g y ua
db ran
⇒ “1.5 Connection diagram for coolantris hoses - vehicles with ad‐
e
tee
ditional heat exchanger”, page 197
utho or
a ac
ss
⇒ “1.6 Connection diagram for coolant hoses - vehicles with aux‐
ce
le
un
pt
iliary heater”, page 201
an
d
itte
y li
erm
⇒ “1.7 Connection diagram for coolant hoses - vehicles with ad‐
ab
ility
ditional heat exchanger and auxiliary heater”, page 205
ot p
wit
is n
⇒ “1.8 Connection diagram for coolant hoses - vehicles with basic
h re
ole,
equipment from week 45/10”, page 209
spec
t to the co
ditional heat exchanger from week 45/10”, page 211
⇒ “1.10 Connection diagram for coolant hoses - vehicles with
rrectne
auxiliary heater from week 45/10”, page 215
ss
ditional heat exchanger and supplementary heater from week
o
cial p
f
45/10”, page 219
inform
mer
1.1 Draining and adding coolant
atio
om
n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
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co lksw
by
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Prote AG.
1. Cooling system/coolant 187


equipment required
♦ Refractometer - T10007 A-
- VAS 6208-
6340-
♦ Coolant system charge unit
- VAS 6096-
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
Draining
o
his
ate
do
priv
cum
or
WARNING
f
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ng
t.
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op
Hot steam may escape when expansion tank is opened. Wear
C py
t. rig
gh
eye protection and protective clothing to avoid eye injuries and
ht
pyri by
Vo
scalding. Cover cap with a cloth and carefully open.
co lksw
by
cted agen
Prote AG.
– Open filler cap on coolant expansion tank.

noise insulation .
188 Rep. gr.19 - Cooling

Depending on equipment.
– Remove spring-type clip -1- and pull coolant hose downwards
off radiator -2-.
AG. Volkswagen AG d
agen oes
ksw
Or by
Vol not
gu
d ara
ise nte
– Detach clip -1-.thor eo
au ra
c
– Separate coolant
ss
hose -2-.
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rm
ab
pe
ility
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es, in part or in w
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Continued for all vehicles
rrectness of i
– Pull off coolant hoses -2- from coolant circulation pump - V178-
l purpos
-1-.
nform
ercia
Note
m
a
com
tion in
Please observe disposal instructions!

r
te o
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s
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Top–up
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Prote AG.


lkswage es n
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♦ Only distilled water may be used for mixing coolant additives.
ir se
d b ran
tee
The use of distilled water ensures optimum protectionuth against
o
or
corrosion. ss
a ac
ce
e
♦ The water used for mixing has a major influence on the effec‐
nl
pt
du
an
tiveness of the coolant. Since water quality differs from country
itte
y li
to country and even region to region, it is necessary to set a
erm
ab
ility
standard for the quality of water to be used. Distilled water
ot p
satisfies all requirements. It is therefore recommended to use
wit
, is n
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distilled water when mixing coolant for topping up or replacing
hole
coolant.
spec
es, in part or in w
t to the co
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
rrectness of i
damage to the motor.
l purpos
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐

rosion damage as well as scaling. Such additives also raise
nform
ercia
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
m
at
om
io
♦ Because of its high boiling point, the coolant improves engine
n
c
in t
r
reliability under heavy loads, particularly in countries with trop‐

o
his
te
ical climates.
a
do
priv
cum
or
♦ The refractometer - T10007A- must be used to determine the

f
en
ng
current anti-freeze value.

t.
yi Co
Cop py
. rig
♦ Frost protection must be guaranteed down to -25°C as a min‐
t
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imum and, in countries with arctic conditions, down to approx. cop Vo
by lksw
-36°C. Increasing the frost protection is permissible only if cli‐ cted agen
Prote AG.
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48 °C. Otherwise,
the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixture ratios:

Frost protection Coolant additive Coolant Distilled
to portion additive 1) water 1)
-25°C 40% 4.4 l 6.6 l
-36°C 50% 5.5 l 5.5 l
1) The quantity of coolant can vary depending upon vehicle equipment.
– Reconnect coolant hoses, and secure them with clamps.

– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank -1-.
– Mount cooling system charge unit - VAS 6096- on adapter -
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move
agen
Ainto
G. Vogreen
lkswagearea.
n AG d
w oes
olks no
– In addition, open d b valve -A- briefly by turning lever inuadirection
yV tg
ran
of flow until expansion
rise tank hose of cooling system charge tee unit
ho
- VAS 6096-
au fills with coolant.
t or
a
ss c
– Close valve -A- again.
ce
e
nl
pt
du
an
– Leave valve -B- open for a further 2 minutes.

itte
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erm
ab
• Vacuum continues to be generated in the cooling system by

ility
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the suction jet pump; the needle of gauge must remain in green
wit
, is n
range.
h re
hole
spec
– Close valve -B-.

es, in part or in w
t to the co
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
rrectness of i
• If the needle does not reach the green zone, repeat the proc‐
l purpos
ess.
• If vacuum drops, cooling system must be checked for leaks.
nf
ercia
or
– Pull off compressed air hose.

m
m
atio
m
– Open valve -A-.

o
n in
or c
thi
e
• The vacuum in the cooling system causes coolant to be ex‐

t
sd
iva
tracted from coolant expansion tank of cooling system charge

o
r
rp
cu
unit - VAS 6096- and the cooling system to be filled.

o
m
f
en
ng
t.
yi Co
– Then, remove cooling system charge unit - VAS 6096- from t. Cop py
coolant expansion tank again.
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote
AG.
noise insulation .

Without cooling system charge unit - VAS 6096- :

– Slowly fill coolant in up to upper marking of hatched field on
expansion tank.
– Fit expansion tank cap.
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
– Check coolant level and top up if necessary. When engine is
at normal operating temperature, the coolant level must be at
the upper mark; when engine is cold, in the middle of the sha‐
ded field.
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
♦ Adapter for cooling system tester - V.A.G 1274/8-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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♦ Adapter for cooling system tester - V.A.G 1274/9-
C py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Check condition
• Engine at operating temperature.

WARNING

– Open cap -1- of coolant expansion tank -2-.

– Place adapter for cooling system tester - V.A.G 1274/8- on
coolant expansion tank.
– Connect cooling system tester - V.A.G 1274 B- .
– Generate about 1.0 bar pressure using hand pump of tester.
DANGER!
Risk of scalding! Before the cooling system tester - V.A.G 1274

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

– Find leaks and rectify.
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter for
cooling system tester - V.A.G 1274/9- on cap -1-.
– Build up pressure using hand pump of cooling system tester.
agen
AG. Volkswagen AG d
o w es n
olks ot g
• The pressure relief valve must open at a pressure
db
y V of 1.6 to ua
ran
1.8 bar. ho
rise tee
t or
au ac
– Renew filler cap, if pressure relief valve
ss does not open as de‐
scribed.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
1.3 Assembly overview - coolant hoses

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - O-ring
❑ Renew if damaged or
leaking
2 - Sleeve
❑ Inserted in union
⇒ Item 3 (page 194) .
3 - Union
4 - O-ring
leaking
5 - Radiator outlet coolant -
G62- n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Removing and installing d byV ua
ran
⇒ page 232 ir se tee
tho
u or
a ac
6 - Retaining clip ss
ce
e
nl
7 - Coolant line
pt
du
an
itte
y li
❑ Connection diagram for
erm
ab
coolant hoses
ility
ot p
⇒ page 195
wit
, is n
h re
8 - Spring-type clip
hole
spec
❑ Hose clip pliers - VAS
es, in part or in w
t to the co
6340- or hose clip pliers
- VAS 6362- are recom‐
mended for installation
of spring-type clips.
rrectness of i
9 - Coolant line
l purpos

coolant hoses
nf
ercia
o
⇒ page 195
rm
m
atio
m
10 - Coolant line
o
n in
or c
thi
e
coolant hoses
t
sd
iva
o
⇒ page 195
r
rp
cu
o
m
f
en
ng
11 - Bolt
t.
yi Co
op py
❑ 9 Nm t. C rig
gh ht
pyri by
12 - Coolant line
co Vo
by lksw
cted agen
Prote
❑ Connection diagram for coolant hoses ⇒ page 195
AG.
13 - Radiator outlet coolant temperature sender - G83-

❑ Removing and installing “single turbo engine” ⇒ page 234 .
❑ Removing and installing “bi-turbo engine” ⇒ page 236 .
14 - Nut
❑ 40 Nm
15 - Continued coolant circulation pump - V51-
16 - Coolant line
17 - Coolant line
18 - Ball thermostat (4/2-way valve)
❑ Thermostat is installed in valve.

❑ Renew completely
19 - Bolt
❑ 15 Nm
1.4 Connection diagram for coolant hoses -

vehicles with basic equipment
⇒ “1.4.1 Vehicles with 62, 75 and 103 kW engine”, page 195
⇒ “1.4.2 Vehicles with 132 kW engine”, page 196
wage
1.4.1 Vehicles with 62, 75 and 103 kW engine byV
olks es n
ot g
ua
d ran
ir se tee
tho
u or
1 - Heat exchanger for heaterss a ac
ce
e
nl
2 - Gear oil cooler
pt
du
an
itte
❑ Only vehicles with dual
y li
erm
ab
clutch gearbox.
ility
ot p
wit
3 - Expansion tank
, is n
h re
hole
4 - Continued coolant circula‐
spec
tion pump - V51-
es, in part or in w
t to the co
5 - Y-thermostat
❑ Opens above approx.
rrectness of i
75 °C
l purpos
⇒ page 232
6 - Non-return valve
nf
ercia
or
❑ Installed in coolant
m
m
atio
hose.
om
n in
or c
7 - Radiator/cooler
thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
9 - Ball thermostat (4/2-way

t.
yi Co
valve) Cop py
t. rig
gh
❑ Thermostat is installed
ht
pyri by
Vo
o
in valve.
c by lksw
cted agen
Prote AG.
10 - Cylinder block
11 - Coolant pump
12 - Intake manifold
13 - Cylinder head
14 - Circulation pump - V55-
15 - Exhaust gas recirculation
cooler

1.4.2 Vehicles with 132 kW engine
1 - Heat exchanger for heater

2 - Gear oil cooler
clutch gearbox.
3 - Expansion tank
4 - Y-thermostat
75 °C
⇒ page 232
tion pump - V51-
hose.
7 - Radiator/cooler
8 - Cylinder block
cooler
❑ With engine oil filter
AG. Volkswagen AG d
⇒ page 485 ksw
agen oes
not
ol
yV gu
11 - Ball thermostat (4/2-way ised b ara
nte
valve) ut
hor eo
a ra
❑ Thermostat is installed ss c
in valve.
ce
e
nl
pt
du
an
itte
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erm
ab
12 - Coolant pump
ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
15 - Cylinder head
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


vehicles with additional heat exchanger
wage
⇒ “1.5.1 Vehicles with 62, 75 and 103 kW engine, without heater olks es n
ot g
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coolant shut-off valve N279 and 2/2-way valve”, page 197sed b ua
ran
ir tee
ho
⇒ “1.5.2 Vehicles with 62, 75 and 103 kW engine, withau heater
t or
ac
coolant shut-off valve N279 and 2/2-way valve”, page 198
ss
ce
le
un
pt
⇒ “1.5.3 Vehicles with 132 kW engine, without heater coolant
an
d
itte
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shut-off valve N279 and 2/2-way valve”, page 199
erm
ab
ility
ot p
⇒ “1.5.4 Vehicles with 132 kW engine, with heater coolant shut-
wit
off valve N279 and 2/2-way valve”, page 200
is n
h re
ole,
1.5.1 Vehicles with 62, 75 and 103 kW engine, without heater coolant shut-off
spec
valve - N279- and 2/2-way valve urposes, in part or in wh
t to the co
rrectne
2 - Y-thermostat
ss
❑ For additional heat ex‐
o
cial p
f
changer for heater unit
inform
mer
atio
55°C
om
n
c
i
or
n
3 - Additional heat exchanger
thi
te
for heater unit
sd
iva
o
pr
cum
r
4 - Gear oil cooler

fo
en
ng
t.
yi
Co
op py
clutch gearbox.
t. C rig
gh ht
pyri by
Vo
5 - Expansion tank
co lksw
by
cted agen
Prote AG.
tion pump - V51-
7 - Y-thermostat
75 °C
⇒ page 232
hose.
9 - Radiator/cooler
10 - Cylinder block
valve)
in valve.

13 - Coolant pump
14 - Cylinder head
17 - Exhaust gas recirculation cooler
1.5.2 Vehicles with 62, 75 and 103 kW engine, with heater coolant shut-off valve
- N279- and 2/2-way valve
AG. Volkswagen AG d
agen oes
1 - Heat exchanger for heater Volksw not
gu
d by ara
e
2 - Additional heat exchanger horis nte
eo
for heater unit aut ra
c
ss
3 - 2/2-way valve
ce
e
nl
pt
du
an
itte
4 - Gear oil cooler
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erm
ab
ility
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clutch gearbox.
wit
, is n
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5 - Expansion tank
hole
spec
es, in part or in w
t to the co
tion pump - V51-
7 - Y-thermostat
rrectness of i
75 °C
l purpos

⇒ page 232
nform
ercia
m
at
om
ion
c
hose.
in t
or
his
ate
9 - Radiator/cooler
do
priv
cum
or
10 - Cylinder block
f
en
ng
t.
yi Co
op
11 - Engine oil cooler C py
t. rig
gh ht
yri by
12 - Ball thermostat (4/2-way op Vo
by c lksw
valve) cted agen
Prote AG.
in valve.
13 - Coolant pump
16 - Cylinder head
17 - Shut-off valve for heater coolant - N279-

1.5.3 Vehicles with 132 kW engine, without heater coolant shut-off valve - N279-
and 2/2-way valve

2 - Y-thermostat
❑ For additional heat ex‐gen AG. Volkswagen AG
does
changer for heater olkunit
swa not
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❑ Opens above risedapprox.
b ara
nte
55°C uth o eo
r
sa ac
3 - Additionals heat exchanger
ce
e
nl
for heater unit
pt
du
an
itte
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4 - Gear oil cooler
erm
ab
ility
ot p
wit
clutch gearbox.
, is n
h re
hole
5 - Expansion tank
spec
es, in part or in w
6 - Y-thermostat
t to the co
75 °C
rrectness of i
⇒ page 232
l purpos

tion pump - V51-
nform
ercia
m
at
om
io
n
c
in t
or
hose.
his
ate
do
riv
9 - Radiator/cooler
p
cum
for
en
g
10 - Cylinder block
n
t.
yi Co
Cop py
11 - Engine oil cooler ht. rig
rig ht
py by
o Vo
12 - Exhaust gas recirculation by c lksw
cted agen
cooler Prote AG.

⇒ page 485
13 - Ball thermostat (4/2-way valve)
14 - Coolant pump
17 - Cylinder head

1.5.4 Vehicles with 132 kW engine, with heater coolant shut-off valve - N279- and
2/2-way valve

for heater unit
3 - 2/2-way valve
4 - Gear oil cooler
clutch gearbox.
5 - Expansion tank
6 - Y-thermostat
75 °C
❑ Removing and installing lkswage es n
o ot g
⇒ page 232 d byV ua
ran
ir se tee
7 - Continued coolant circula‐ autho
or
ac
tion pump - V51- ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
hose.
ility
ot p
wit
, is n
9 - Radiator/cooler
h re
hole
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spec
es, in part or in w
t to the co
cooler
rrectness of i
l purpos

⇒ page 485
nf
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vehicles with auxiliary heater
⇒ “1.6.1 Vehicles with 62, 75 and 103 kW engine, without heater
⇒ “1.6.2 Vehicles with 62, 75 and 103 kW engine, with heater
valve - N279- and 2/2-way valve

2 - Supplementary heating
4 - Gear oil cooler agen
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t to the co
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l purpos
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⇒ page 232
l purpos
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ss

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form
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2/2-way valve

4 - 2/2-way valve
5 - Gear oil cooler
clutch gearbox.
6 - Expansion tank
7 - Y-thermostat
75 °C
⇒ page 232
tion pump - V51-
hose.
11 - Cylinder block
13 - Exhaust gas recirculation wage
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⇒ page 485 s
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nl
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valve)
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t to the co
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rrectness of i

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and auxiliary heater
1.7.1 Vehicles with age62,

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ss for heater
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hole
spec
5 - Gear oil cooler
es, in part or in w
t to the co
clutch gearbox.
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rrectness of i

l purpos
tion pump - V51-

8 - Y-thermostat
nform
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m
at
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75 °C
ion
c
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r

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e
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at
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py
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valve)
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14 - Coolant pump
16 - Cylinder head


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wit
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7 - Expansion tank
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tion pump - V51-
9 - Y-thermostat
rrectne
75 °C
ss
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inform
mer
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AG.
14 - Cylinder block
15 - Coolant pump
17 - Cylinder head

and 2/2-way valve

for heater unit
5 - Gear oil cooler
clutch gearbox.
6 - Expansion tank
7 - Y-thermostat
75 °C
⇒ page 232
AG. Volkswagen AG d
8 - Continued coolant circula‐ ksw
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ab
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11 - Cylinder block
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ss
valve) o
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form
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15 - Coolant pump
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py by
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2/2-way valve

for heater unit
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clutch gearbox.
7 - Expansion tank
8 - Y-thermostat agen
AG. Volkswagen AG d
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9 - Continued coolant circula‐ pt

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hose.
spec
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ss
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atio
⇒ page 485
om
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cted AG.
agen
18 - Cylinder head


vehicles with basic equipment from
week 45/10
⇒ “1.8.1 Vehicles with 62, 75 and 103 kW engine”, page 209
⇒ “1.8.2 Vehicles with 132 kW engine”, page 210
1.8.1 Vehicles with 62, 75 and 103 kW engine

2 - Gear oil cooler
clutch gearbox.
3 - Expansion tank
AG . Volkswagen AG
agen does
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tion pump - V51- by
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5 - Radiator/cooler
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7 - Cylinder block
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d
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valve)
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ole,
in valve. spec
t to the co
9 - Coolant pump
rrectne
11 - Cylinder head
ss

o
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cooler
inform
mer

atio
⇒ page 492
om
n
c
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or

thi
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iva
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wage
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Edition 08.2016
olkswagen AG d
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Vol t gu
by ara
1.8.2 Vehicles with 132 kW engine ed
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du
an
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2 - Gear oil cooler
erm
ab
ility
ot p
clutch gearbox.
wit
, is n
h re
hole
3 - Expansion tank
spec
es, in part or in w
t to the co
tion pump - V51-
5 - Radiator/cooler
rrectness of i
l purpos

cooler
nf
ercia
o
rm
m
⇒ page 485
atio
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n in
c
8 - Cylinder block
or
thi
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rp
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valve)
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in valve. C py
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agen
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AG. Volkswagen AG d
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by V California 2010 ➤ , Caravellet g2010
ua ➤ , Multivan 2010 ➤ , Transporter 20 ...
ed ran
oris 4-cylinder diesel engine (2.0teel engine, common rail) - Edition 08.2016
th or
au ac
ss
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un
pt
an
d
itte
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erm
from week 45/10
ab
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spec
t to the co
rrectne
s
s o
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form
mer
atio
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n
c
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pr
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2 - Y-thermostat
fo
en
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t.
yi
Co
op py
. C rig
ht ht
rig by
py
❑ Opens above approx. co Vo
by lksw
55°C
cted agen
Prote AG.

for heater unit
4 - Gear oil cooler
clutch gearbox.
5 - Expansion tank
tion pump - V51-
7 - Radiator/cooler
9 - Cylinder block
valve)
in valve.
11 - Coolant pump
13 - Cylinder head
cooler
⇒ page 492

4-cylinder diesel engine (2.0 l engine, common rail) o-lkEdition
en AG. V
swagen A08.2016
G ag does
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Vol gu
1.9.2 Vehicles with 62, 75 and 103 kW engine, with heater coolant shut-off valve by ara
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- N279- and 2/2-way valve th eo
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s
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un
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for heater unit ot p
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3 - 2/2-way valve
ole,
spec
4 - Expansion tank
t to the co
5 - Gear oil cooler
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clutch gearbox.
ss
tion pump - V51-
o
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f in
7 - Radiator/cooler
form
mer
atio
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n
c
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valve)
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in valve.
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op
❑ Renew completely C py
t. rig
gh ht
yri by
10 - Cylinder block op Vo
by c lksw
cted agen
Prote
11 - Coolant pump
AG.
13 - Cylinder head
cooler
⇒ page 492
16 - Shut-off valve for heater
coolant - N279-

and 2/2-way valve

2 - Y-thermostat
55°C
for heater unit
4 - Expansion tank
tion pump - V51-
6 - Radiator/cooler
8 - Cylinder block
cooler
⇒ page 485
valve)
in valve.
11 - Coolant pump
12 - Intake manifold AG. Volkswagen AG d
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13 - Cylinder head ed b ara
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c
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or
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213
op Vo
by c lksw
Prote
cted AG.
agen 1. Cooling system/coolant
2/2-way valve

for heater unit
3 - 2/2-way valve
4 - Gear oil cooler
clutch gearbox.
5 - Expansion tank
tion pump - V51-
7 - Radiator/cooler
8 - Cylinder block
cooler AG. Volkswagen AG d
agen oes
ksw
❑ With engine oil filter by
Vol not
gu
ara
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un
pt
valve)
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d
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rm
ab
pe
in valve.
ility
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wit
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12 - Coolant pump
spec
es, in part or in w
t to the co
rrectness of i
coolant - N279-
l purpos
16 - Cylinder head
nform
mercia
a
com
tion in
r
te o
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s
iva
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t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.


vehicles with auxiliary heater from week
45/10

4 - Expansion tank
tion pump - V51-
6 - Radiator/cooler
7 - Cylinder block
olkswagen AG
en AG. V
9 - Ball thermostat (4/2-way ksw
ag does
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Vol
valve) ed
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10 - Coolant pump
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erm
ab
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ot p
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12 - Cylinder head
h re
hole
spec

es, in part or in w
cooler
t to the co

⇒ page 492
rrectness of i
l purpos
nf
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orm
m
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n in
or c
thi
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valve)
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12 - Coolant pump
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cooler
l purpos

⇒ page 492
nf
ercia
or

m
m
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coolant - N279-
om
n in
or c
thi
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a
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rp
cu
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t.
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ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

and 2/2-way valve

4 - Gear oil cooler
clutch gearbox.
5 - Expansion tank
6 - Continued coolant circula‐ Volkswa
tion pump - V51- swa
gen AG
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does
k not
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7 - Radiator/cooler
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8 - Cylinder
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ss
ce
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nl
pt
du
an
itte
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ab
cooler
ility
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wit
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hole
⇒ page 485 spec

es, in part or in w
t to the co
valve)
rrectness of i
in valve.
l purpos
12 - Coolant pump
nform
ercia
m
at
om
14 - Cylinder head
ion
c
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or
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ate
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for
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cted agen
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2/2-way valve

4 - 2/2-way valve
5 - Gear oil cooler
clutch gearbox.
6 - Expansion tank
tion pump - V51-
8 - Radiator/cooler
9 - Cylinder block
cooler
⇒ page 485
12 - Ball thermostat (4/2-way n AG. Volkswagen AG do
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valve) byV
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13 - Coolant pump
itte
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erm
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15 - Cylinder head h re
hole

spec
es, in part or in w
coolant - N279-
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.


and supplementary heater from week
45/10
⇒ “1.11.1 Vehicles with 62, 75 and 103wkWagenengine, withoutAG
AG. Volkswagen heater
does
coolant shut-off valve N279 and 2/2-way
yV
olks valve”, page 219 not
gu b ara
ed
⇒ “1.11.2 Vehicles with 62,h75or and 103 kW engine, with heater
is nte
e
coolant shut-off valve N279
s aut and 2/2-way valve”, page 220 or
ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

for heater unit
nf
ercia
o
rm
m
atio
m
5 - Expansion tank
o
n in
or c
thi
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sd
a
tion pump - V51-

iv
o
r
rp
cu
o
7 - Radiator/cooler
f
en
ng
t.
yi Co
op
8 - Cylinder block
C py
ht. rig
rig ht
py by
9 - Engine oil cooler co Vo
by lksw
cted agen
Prote
AG.
valve)
in valve.
11 - Coolant pump
13 - Cylinder head
cooler
⇒ page 492

California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010wa➤ ge,n Transporter
AG. Volkswagen20
AG...
does
ks not
4-cylinder diesel engine (2.0 l engine, common brail)
y V - Edition 08.2016
ol
gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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, is n
h re
hole
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es, in part or in w
for heater unit
t to the co
5 - 2/2-way valve
rrectness of i
6 - Expansion tank
l purpos

tion pump - V51-
nform
ercia
8 - Radiator/cooler
m
at
om
io
9 - Cylinder block
n
c
in t
or
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e

at
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priv
cum
for
en
g
valve)
n
t.
yi Co
op py
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gh ht
in valve. yri
p by
co Vo
by lksw
❑ Renew completely cted agen
Prote AG.
12 - Coolant pump
14 - Cylinder head
cooler
⇒ page 482
coolant - N279-
hose.

and 2/2-way valve

for heater unit
5 - Gear oil cooler
clutch gearbox.
6 - Expansion tank
tion pump - V51-
8 - Radiator/cooler
9 - Cylinder block
cooler
⇒ page 485
12 - Ball thermostat (4/2-way wage
es n
valve) yV
olks ot g
ua
d b
❑ Thermostat is installed o
ir se
ran
tee
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ac
ss
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13 - Coolant pump an
d
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rm
ab
pe
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15 - Cylinder head
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Cop py
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2/2-way valve

for heater unit
5 - 2/2-way valve
6 - Gear oil cooler
clutch gearbox.
7 - Expansion tank
tion pump - V51-
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10 - Cylinder block
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2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump and ball thermostat
(4/2-way valve)”, page 223
⇒ “2.2 Assembly overview - Continued coolant circulation pump
V51 ”, page 224
⇒ “2.3 Removing and installing coolant pump”, page 225
⇒ “2.4 Removing and installing continued coolant circulation
pump V51 ”, page 226
⇒ “2.5 Removing and installing 4/2-way valve with thermostat”,
page 228
⇒ “2.6 Removing and installing Y-thermostat .”, page 232
⇒ “2.7 Removing and installing coolant temperature sender G62
”, page 232
⇒ “2.8 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 234
2.1 Assembly overview - coolant pump and ball thermostat (4/2-way valve)
1 - Bolt
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2. Coolant pump, regulation of cooling system 223

2.2 Assembly overview - Continued coolant circulation pump - V51-
1 - Nut
❑ 60 Nm
2 - Bolt
❑ 1.5 Nm
3 - Sleeve
4 - Rubber mounting
5 - Holder
6 - Coolant hose
❑ Return flow to exhaust
gas recirculation cooler
7 - Coolant hose
❑ Feed line from radiator
tion pump - V51-
⇒ page 226
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Removing
Note
Always renew gaskets and seals.


– Loosen toothed belt tensioning roller and remove toothed belt

from camshaft sprocket ⇒ page 122 .
– Unscrew bolts -1- of coolant pump -2- and carefully remove
coolant pump.
Installing
Note
♦ The coolant pump plug faces downwards.

♦ Moisten new O-ring with coolant.
– Insert coolant pump into cylinder block and tighten bolts.

– Install and tension toothed belt ⇒ page 122 .
Torque settings
2.4 Removing and installing continued coolant circulation pump - V51-
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Removing
noise insulation .
– Loosen hose clip and push front of air intake pipe towards the
right.
– Clamp off coolant hoses using hose clamps, up to 25 mm -
3094- .

– Remove coolant hoses. To do this, loosen spring-type clips

-2-.
– Collect escaping coolant with a cloth.
– Unscrew nut -5- and remove continued coolant circulation
pump - V51- -1- with bracket.
Installing
noise insulation .
– Check coolant level ⇒ page 187 .
Torque settings
♦ ⇒ “2.2 Assembly overview - Continued coolant circulation
2.5 Removing and installing 4/2-way valve with thermostat

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equipment required
- VAS 6208-
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2. Coolant pump, regulation of cooling system
AG.
– Unscrew bolts -1- and bolt -4- from front torque reaction sup‐
port -3-.
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Note
To remove the thermostat, the water pipe must first be removed.
– Loosen water pipe bolts and pull the pipe slightly backwards.
– Removing and installing exhaust gas recirculation cooler “bi-
turbo engine” ⇒ page 485 .
– Loosen water pipe bolts and pull the pipe slightly backwards.

Note

-3-.
Note
♦ The ball thermostat (4/2-way valve) must be removed together

with the “small” coolant hose.
♦ Before installing, coat the connection of the ball thermostat
(4/2-way valve) and the seal on the coolant pipe with coolant.
– Open clip -3- and pull coolant hose -4- off connection.
– Open clip -1- and pull coolant hose -2- off connection.
– Unscrew bolts -5- and pull off ball thermostat (4/2-way valve)
-6- together with the coolant hose -2-.
– Open clip -8- and pull coolant hose -2- off ball thermostat (4/2-
way valve) -6-.
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♦ ⇒ “3.1.1 Assembly overview - exhaust gas recirculation cooler,

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2.7 Removing and installing coolant temper‐

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Note
Insert new coolant temperature sender - G62- immediately into

union to avoid loss of coolant.


– Lay coolant pipe to one side.
– Disconnect connector -4- at coolant temperature sender -
G62- .
– Place several cloths under the union to absorb escaping cool‐
ant.
– Pull off retaining clip -3- and pull coolant temperature sender
- G62- out of screw connection.
Installing
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WARNING

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Note
Insert new coolant temperature sender - G83- immediately into

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4 - Bolt
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5 - Sealing cover
❑ Check using cooling
system tester - V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure: 1.4 to
1.6 bar
6 - Expansion tank
❑ With coolant tempera‐
ture display sender -
G32- .
❑ Test cooling system for
leaks using cooling sys‐
tem tester - V.A.G 1274-
and adapter for cooling
system tester - V.A.G
1274/8- ⇒ page 192 .
7 - Connector
8 - Bolt
❑ 5 Nm
9 - Upper radiator mounting
11 - Cowling with radiator fan - V7-

12 - Bolt
❑ 5 Nm
13 - Bolt
❑ 5 Nm
14 - Connector
15 - Intercooler
16 - Lower radiator mounting
17 - Lower coolant hose
3.2 Assembly overview - radiator cowl and radiator fan
1 - Radiator/cooler
2 - Radiator fan
3 - Bolt
❑ 5 Nm
4 - Bolt
❑ 5 Nm
5 - Retainer tab
❑ Must be engaged in ra‐
diator.
6 - Radiator cowl
⇒ page 245
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– Detach lower right coolant hose -3- from holder -2-. Remove
en
ng
t.
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air duct -1- holder t. Cop py
rig
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– Unscrew bolt for bumper carrier. yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolt -arrow- from radiator mounting on right and left.

– Pull back securing lever -1- onto stop lkswage es n
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ed ran
– Push down securing lever -2- and pull off
or connector
is tee
th or
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– Remove charge air cooler. ss
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le
un
⇒ “2.3 Removing and installing charge air cooler”, page 350
pt
an
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itte
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erm
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ility
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ole,
spec
t to the co
– Remove spreader rivets -1- and remove air duct -2- upwards.
rrectness o
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f inform
mer
atio
om
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t.
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Cop py
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– Open spring-type clips -arrows- and pull coolant hoses -1- and yri
p by
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-2- off radiator.
c by lksw
cted agen
Prote AG.
– Pull out power steering pipe -1- from mountings -2 … 4-.
Note
Remove the two holders for the servo steering pipe only if the
radiator is to be replaced.


– Squeeze catch -arrow- and pull condenser forwards a little.
lkswage es n
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byV ua
d ran
ir se tee
tho
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a ac
– Squeeze catch -arrow- and pull condenser s-2-
s off radiator
-1-.
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nl
pt
du
an
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erm
ab
Caution
ility
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• Do not bend or stretch the refrigerant lines.
h re
hole
spec
• The condenser must be held in the “2 o'clock position”
es, in part or in w
when the radiator is being removed.
t to the co
• A second mechanic is needed to remove the radiator.
rrectness of i
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orm
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– Lift condenser -1- out of the left holder -2- and right holder
o
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-3- and place it on the bumper.

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Cop py
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pyri by
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Prote AG.

– Unscrew bolt -2- from upper left and right radiator mounting.
– Press right and left catches -1- together.
– Press the two radiator mountings downwards into the radiator.
Caution
• During further removal work, make sure that the refriger‐

ant lines are not bent or stretched excessively.
– Do not bend or stretch the refrigerant lines -1- and -2- exces‐
sively
– Hold condenser -1- in “2 o'clock position” (2nd mechanic).

– Carefully remove radiator -2- towards the left in direction of
-arrow-.
When doing so, guide radiator -2- past refrigerant lines the bump‐
er carrier.
If the radiator is to be renewed, the cowling is to be removed to‐
gether with the radiator fan - V7- ⇒ page 245 .
AG. Volkswagen AG d
Installing lksw
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Install in reverse order of removal,
ised observing the following: ara
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– Insert lower radiator mounting -1- into lock carrier -2- trans‐
nl
pt
du
verse to direction of travel, and then turn it 90".

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erm
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ility
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spec
es, in part or in w
t to the co
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Cop py
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244
by c lksw
cted
Rep. gr.19 - Cooling
agen
Prote AG.
olkswagen AG
4-cylinder diesel engine (2.0w en AG. V common
al gengine, rail)
does- Edition 08.2016
lkso n ot g
yV ua
edb ran
– When installing, make sure that the catches -1- ho
risof the radiator tee
mounting on the left and right at the top haveaut engaged com‐ or
ac
pletely in the lock carrier. ss
ce
le
un
pt
Vehicles with “bi-turbo engine”:
an
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erm
ab
Observe instructions for hose connections with screw-type clips
ility
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⇒ page 347 .
wit
is n
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– Installing charge air cooler “bi-turbo engine” ⇒ page 350 .
ole,
spec
Vehicles with “single turbo engine”:
t to the co
Note instructions for installing hose connections with plug-in con‐
nectors ⇒ page 347
rrectne
– Installing charge air cooler “single turbo engine”
⇒ page 352 .
ss
o
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f in
form
mer
atio
Torque settings
om
n
c
i
♦ ⇒ “3.1 Assembly overview - radiator, radiator fan”, page 238
or
n thi
te
sd
va
♦ ⇒ “2.1 Assembly overview - charge air system”, page 344

i
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cum
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t.
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Co
Cop py
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Vo
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♦ Noise insulation; Assembly overview – noise insulation ⇒ by c lksw
cted agen
General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Prote AG.
3.4 Removing and installing radiator cowl

with radiator fan - V7-
Removing
– Removing radiator ⇒ page 240 .
– Remove bracket for servo line.
– Unscrew bolts -arrows- and remove cowling together with ra‐
diator fan - V7- from radiator.

– Push back locking lug -arrow- and remove cowling together

with radiator fan - V7- from radiator.
Installing
– Insert cowling together with radiator fan - V7- into radiator with
locking lug first -arrow-.
– Installing radiator ⇒ page 240 .
Torque settings
AG. Volkswagen AG d
agen oes
♦ ⇒ “3.1 Assembly overview - radiator, radiator fan”, page 238 olksw not
y V gu
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♦ ⇒ “2.1 Assembly overview - charge air system”, page 344horis nte
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Bolt for servo line holder 5 Nm
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tion in
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Prote AG.

olkswagen AG
n AG. V4-cylinder
swage diesel
does engine (2.0 l engine, common rail) - Edition 08.2016
olk not
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20 – Fuel supply system

tho eo
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pt
1 Procedure when filling with incorrect
an
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fuel
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ility
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⇒ “1.1 Procedure when filling with incorrect fuel”, page 247
h re
hole
spec
1.1 Procedure when filling with incorrect fuel
es, in part or in w
t to the co
Caution
rrectness of i
Irreparable damage to high-pressure components, especially
l purpos
the high-pressure pump due to lack of lubrication though diesel

can occur when filling fuel tank with incorrect fuel. Damage due
to seizure and metal particles can be expected. These metal
nform
ercia
particles will probably cause further damage to pressure reg‐

ulating valves and injectors.
m
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tion in
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Here are the solutions for two different cases of filling with incor‐
s
iva
do
r
rect fuel:
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♦ 1st scenario: filling with incorrect fuel was detected BEFORE

n
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op
starting the engine and the engine was NOT started
C py
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⇒ page 247
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♦ 2nd scenario: filling with incorrect fuel was detected AFTER
cted agen
Prote AG.
starting the engine. Impurities or incorrect type of fuel has en‐
tered the fuel system and has reached the high-pressure
system ⇒ page 248 .
Perform the following steps:
Procedure for 1st scenario
Caution
• It is not permissible to empty the fuel tank with the fuel

suction device - VAS 5190- via the filler neck.
♦ If the fuel tank is emptied with the fuel suction device - VAS
5190- via the filler neck, the non-return valve -arrow- will
be damaged.
Non-return valve -arrow- in filler neck

– Do not switch on ignition.
1. Procedure when filling with incorrect fuel 247

– Release and pull off connector -5- of supplementary fuel pump

- V393- in engine compartment.
– Remove fuel tank ⇒ page 252 .
– Remove fuel delivery unit and drain ⇒ page 257 .
– Check strainer and clean if soiled.
– Use the fuel suction device - VAS 5190- to completely empty
the fuel tank via the fuel delivery unit.
– Install fuel delivery ounit
lksw ⇒ page 257 .
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– Install fuel tankir se ⇒ page 252 .
d ran
tee
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– Attach connector
ss
au
-5- to supplementary fuel pump - V393- inac
engine compartment.
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du
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Note
ility
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For models in which the fuel pump is activated when the door is
h re
opened, the fuel filter must be renewed.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fill fuel tank with 5 litres of diesel fuel. Then carry out function
l purpos
“Bleeding fuel system” ⇒ Vehicle diagnostic tester.

nf
ercia

or

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– Fill fuel tank completely with diesel fuel.

t.
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Cop py
.
– Carry out road test.
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co
Procedure for 2nd scenario
by lksw
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Prote AG.
Caution

be damaged.

– Do not switch on ignition.
248 Rep. gr.20 - Fuel supply system

– Release and pull off connector -5- of supplementary fuel pump

- V393- in engine compartment.
– Remove fuel delivery unit and replace with a new one
⇒ page 257 . wage
e ks s no
Vol t gu
– Use the fuel suction deviceed-byVAS 5190- to completely empty ara
the fuel tank via the fuel
ho delivery unit.
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au ra
– Check fuel tank for sdirt
s and filings. c
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nl
pt
– If necessary, clean fuel tank.
du
an
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Procedure - no filings in fuel tank
erm
ab
ility
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– Renew high-pressure pump ⇒ page 454 .
wit
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h re
– Remove metering unit of »old« high-pressure pump and check
hole
spec
for filings.
es, in part or in w
t to the co
If filings are found in metering unit, renew all other high-pressure
components:
rrectness of i
♦ High-pressure lines ⇒ page 406 .
l purpos
♦ High-pressure accumulator (fuel rail) including fuel pressure

regulating valve - N276- and fuel pressure sender - G247- .
⇒ page 403
nf
ercia
or
♦ Injectors (piezo injectors) ⇒ page 412
m
m
atio
m
♦ Fuel return lines (overflow oil lines) ⇒ page 373

o
n in
or c
thi
e
Procedure - filings in fuel tank

t
sd
iva
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rp
– Renew all high-pressure components: cu

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f
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ng
t.
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♦ High-pressure pump ⇒ page 454 .
Co
Cop py
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♦ High-pressure lines ⇒ page 406 .
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pyri by
Vo
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by c lksw
♦ High-pressure accumulator (fuel rail) including fuel pressure cted agen
Prote AG.
regulating valve - N276- and fuel pressure sender - G247- .
⇒ page 403
♦ Injectors (piezo injectors) ⇒ page 412
♦ Fuel return lines (overflow oil lines) ⇒ page 373
Continuation for all vehicles
– Install fuel delivery unit ⇒ page 257 .
– Install fuel tank ⇒ page 252 .
– Renew fuel filter ⇒ Maintenance ; Booklet 19 .
1. Procedure when filling with incorrect fuel 249

– Attach connector -5- to supplementary fuel pump - V393- in

engine compartment.
– Fill fuel tank with 5 litres of diesel fuel. Then carry out function
“Bleeding fuel system” ⇒ Vehicle diagnostic tester.
. Volkswagen AG
gen AG does
Vol
ksw
a
not
sure pump are unbolted, removed or renewed, “Bleeding ed
by fuel gu
ara
system” function must be carried out to bleed fuel
ho system us‐
ris nte
eo
ing ⇒ Vehicle diagnostic tester. sa
ut ra
c
s
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e
nl
pt
total of 3 times in the process. The process must not be ter‐ du
an
itte
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ab
ility
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– Fill fuel tank completely with diesel fuel.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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thi
te
sd
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

2 Fuel tank
⇒ “2.1 Assembly overview - fuel tank”, page 251
⇒ “2.2 Removing and installing fuel tank”, page 252
2.1 Assembly overview - fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
1 - Fuel tank
⇒ page 252
2 - Bush
3 - Earth connection
4 - Sealing ring
❑ Renew if damaged
❑ Moisten with fuel when
installing
AG. Volkswagen AG d
agen oes
5 - Fuel system pressurisation Vol
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pump - G6- with fuel gauge ed by ara
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sender - G- ris
utho eo
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❑ Note installation
ss posi‐ c
tion on fuel tank
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pt
du
⇒ page 252
an
itte
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❑ To remove, first remove

erm
ab
fuel tank ⇒ page 252 .

ility
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fuel gauge sender

hole
spec
⇒ page 258 .
es, in part or in w
t to the co
6 - Union nut
❑ 80 Nm
rrectness of i
❑ Remove and install us‐

ing union nut tool -
l purpos
3217- .
7 - Supply pipe
nform
ercia
❑ To fuel filter
m
⇒ page 259 .
at
om
ion
❑ Clipped onto fuel tank.

c
in t
or
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e

at
do
riv
❑ Black
p
cum
for
en
g
❑ To pull off flange, press release buttons on connecting piece

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8 - Return line
t. C rig
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❑ Only in vehicles with auxiliary heater cop Vo
by lksw
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❑ Blue marking
Prote AG.
❑ Clipped onto fuel tank.

2. Fuel tank 251

9 - Bolt
❑ 11 Nm
10 - Rubber cup
❑ During installation, fit rubber cup in the body until it latches fully into place at the top and bottom
11 - Bolt
12 - Sealing cover
❑ Renew gasket if damaged.
13 - Bolt
❑ 26 Nm
14 - Tensioning straps
❑ Observe installation position
❑ Ensure firm seating. AG. Volkswagen AG d
agen oes
olksw not
15 - Return line d by V gu
ara
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❑ From fuel filter ⇒ page 259 . thor eo
au ra
❑ Blue or brown ss c
ce
le

un
pt
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ility
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Installation position of fuel gauge sender
hole
spec
Marking on sender flange must align with the marking on fuel tank
es, in part or in w
-arrows-.
t to the co
Connections for blue or blue-marked return line -1- and black
supply line -2- are marked with an arrow on fuel gauge sender
rrectness of i
flange.
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Note
nform
ercia
After installing fuel gauge sender, check whether fuel supply and
m
a
com
ti
return lines are still clipped onto fuel tank.

on in
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2.2 Removing and installing fuel tank

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Caution t. C rig
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The fuel pump must not be allowed to run when the fuel tank Prote
cted agen
AG.
The fuel tank must contain at least 5 litres of fuel.


equipment required
♦ Key for union nut - 3217-
1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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nl
pt
du
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
or
Removing
m
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atio
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Caution
thi
te
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f

en
ng
t.
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op
• If the fuel tank is to be emptied, the fuel system pressuri‐
C py
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sation pump - G6- and fuel gauge sender - G- must first
rig ht
py by
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be removed, whereupon the fuel tank can be emptied by c lksw
cted agen
through the ensuing aperture. Prote AG.
be damaged.
2. Fuel tank 253


– Note safety precautions before starting installation work
⇒ page 1 .
– Observe rules for cleanliness ⇒ page 9 .
Note
The battery earth must be disconnected for continued work. Be‐

fore doing so, check whether a coded radio is fitted in the vehicle.
Then obtain anti-theft coding first if necessary.
– Open fuel filler flap and unscrew cap.

– Clean area around fuel filler neck.
– Loosen bolt, then pull rubber cup off filler neck, and remove it.
– Remove earth wire.
– Unscrew bolt from filler neck.
– Remove front left underbody cladding -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
– Remove middle left underbody cladding -arrow-.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.

– Press securing ring to release fuel lines and then detach fuel
supply line -1- and return line -2-.
Vehicle with auxiliary heater
– Remove clip -5-.
– Pull hose -6- off the fuel line -3-.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - V.A.G 1383 A- .
– Lower engine and gearbox jack - V.A.G 1383 A- just enough
to allow connector to be pulled off fuel pump flange.
– Pull connector off fuel pump flange and unclip wire from fuel
tank.
– Unclip wiring harness -1- from fuel tank.

– Lower fuel tank.
If the fuel tank is to be replaced:
– Unclip and remove supply line -2- and return line -3- from fuel
tank. en AG. V
olkswagen AG
ag does
ksw not
– If vehicle has an auxiliary heater, unclip and remove Vol fuel line gu
by ara
-4- from fuel tank. ris
ed
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ut
If necessary: ss
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c
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e
– Remove fuel delivery unit ⇒ page 257 .

nl
pt
du
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– Use the fuel suction device - VAS 5190- to completely empty
erm
ab
the fuel tank via the fuel delivery unit.
ility
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Installing
h re
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
The fuel pump must not be allowed to run when the fuel tank
l purpos
The fuel tank must contain at least 5 litres of fuel. nf

ercia
orm
m
– Push connector onto fuel pump flange and clip wire onto fuel
atio
m
tank.
o
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te
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a
– Clip fuel lines -2- to -4- onto fuel tank.

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– Clip wiring harness -1- onto fuel tank.

f
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pyri by
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co lksw
by
cted agen
Prote AG.
2. Fuel tank 255

– Connect fuel supply line -1- and return line -2-. Connections
for fuel lines must engage audibly when joined.
– Push hose -6- onto fuel line -3- as far as the mark -4-.
– Attach left underbody cover ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody cover; Removing and installing un‐
derbody covers .
Torque settings
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 251
♦ Underbody cladding; Assembly overviews ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cladding; Assembly
overview - underbody cover
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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pt
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ab
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wit
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hole
spec
es, in part or in w
t to the co
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nform
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com
tion in
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te o
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en
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t.
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Cop py
t. rig
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by
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Prote AG.

3 Fuel delivery unit, fuel gauge sender

⇒ “3.1 Removing and installing fuel delivery unit”, page 257
⇒ “3.2 Removing and installing fuel gauge sender G ”,
page 258
3.1 Removing and installing fuel delivery

unit
♦ Key for union nut - 3217-
Removing
– Release connections for blue or blue-marked return line -1-
and black supply line -2- and pull from fuel pump unit.
– Release connector -3-n Aand
wage
G. Voremove
lkswagenitAG
from
doe fuel delivery unit.
olks s no
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spec
– Unscrew union nut with union nut tool - 3217- .

t to the co
– Take fuel delivery unit out of the fuel tank.

Installing
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
3. Fuel delivery unit, fuel gauge sender 257

Marking on sender flange must align with the marking on fuel tank
-arrows-.
Connections for blue or blue-marked return line -1- and black
supply line -2- are marked with an arrow on fuel gauge sender
flange.
Torque settings
lkswage es n
o ot g
yV
3.2 Removing and installing fuel gauge ir se
d b ua
ran
tee
sender - G- tho
u or
a ac
ss
Removing
ce
le
un
pt
an
d
itte
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erm
ab
ility
– Remove fuel system pressurisation pump - G6- .
ot p
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is n
– Release connector lugs on lines -3- and -4- and pull off.
h re
ole,
spec
– Lift securing tabs -1- and -2- using a screwdriver, and pull off
fuel gauge sender - G- downwards -arrow-.
t to the co
Installing
rrectne
– Insert fuel gauge sender - G- into guides on fuel pump and
s
press upwards until it engages.
s o
cial p
f in
Torque settings
form
mer
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4 Fuel pump
⇒ “4.1 Assembly overview - supplementary fuel pump V393 ”,
page 259
⇒ “4.2 Removing and installing supplementary fuel pump V393 ”,
page 261
⇒ “4.3 Checking supplementary fuel pump V393 ”, page 262
⇒ “4.4 Checking delivery pressure of fuel system pressurisation
pump G6 ”, page 264
⇒ “4.5 Checking fuel delivery rate of fuel system pressurisation
⇒ “4.6 Checking voltage supply of fuel system pressurisation
⇒ “4.7 Checking current draw of fuel system pressurisation pump
G6 ”, page 269
4.1 Assembly overview - supplementary fuel pump - V393-

1 - Connector
2 - Rubber mounting AG. Volkswagen AG d
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3 - Supplementary e d fuel pump -
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V393- hor eo
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❑ Removing
ss and installing c
⇒ page 261
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❑ To supplementary fuel
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ole,
spec
❑ To be clipped on fuel fil‐

t to the co
ter with identification -

VM-.
❑ To pull off, press release
rrectne
buttons on connecting
piece.
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❑ Check for secure seat‐

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❑ Black
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6 - Return line
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❑ From supplementary
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❑ To pull off, press release

buttons on connecting
piece.
❑ Check for secure seat‐
ing.
4. Fuel pump 259

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❑ Blue marking tho e or
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7 - Return line
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❑ To fuel tank
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❑ To be clipped on fuel filter with identification -RT-.
rm
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❑ To pull off, press release buttons on connecting piece.
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❑ Check for secure seating.
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❑ Blue marking
spec
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8 - Supply pipe
❑ From fuel tank
❑ To be clipped on fuel filter with identification -VF-.
rrectness of i
❑ To pull off, press release buttons on connecting piece.
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❑ Check for secure seating.

❑ Black
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9 - fuel filter.
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❑ Ensure correct installation position in bracket, as shown in illustration.
on in
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❑ Without water drain screw. Draining water from fuel filter is no longer possible.
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To guarantee immediate engine C py
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fuel system must be bled ⇒ Vehicle
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❑ Removing and installing ⇒ Maintenance ; Booklet 19

10 - Holder
❑ For return line ⇒ Item 6 (page 259)
❑ Secured to retainer ⇒ Item 11 (page 260) and supply line ⇒ Item 5 (page 259)
11 - Holder
❑ For fuel filter.
12 - Nut
❑ 10 Nm
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ 10 Nm
15 - Fastener
❑ For return line of power-assisted steering system
16 - Fastener
17 - Holder
❑ For supplementary fuel pump - V393-
18 - Supply pipe
❑ From fuel tank
20 - Cable bracket
❑ Attached to bracket item 17 ⇒ Item 17 (page 260)

4.2 Removing and installing supplementary

fuel pump - V393-
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– Detach fuel line -1- and -3- from the holder -2-. cop Vo
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– Remove bracket -2-.
AG.
– Collect escaping fuel with cleaning cloths.

– Remove clip -4- and pull fuel line -3- off the supplementary fuel
pump - V393- .
4. Fuel pump 261


– Detach connector of wiring harness -3- from bracket.
– Detach wiring harness -3- from clip -4-.
– Remove nuts -2- (qty. 2) and bracket -1-.
– Collect escaping fuel with cleaning cloths.
– Open clip -2- and pull fuel line -1- off the bottom of supple‐
mentary fuel pump - V393- -3-.
Installing
ing ⇒ Vehicle diagnostic tester. en AG. V
olkswagen AG
ag does
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♦ This process takes 130 seconds. Fuel pumps are y Vactuated a
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total of 3 times in the process. The process omust
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Torque settings
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♦ ⇒ “4.1 Assembly overview - supplementary fuel pump V393 ”,

itte
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page 259
erm
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spec
tank
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4.3 Checking supplementary fuel pump -

V393-
rrectne

ss o
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♦ K-Jetronic pressure tester - V.A.G 1318-

inform
mer
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Test conditions:
• Battery voltage at least 12.5 V.
• Fuel filter OK.

• Fuel tank: level min »reserve«.

• Ignition switched off
– Note safety precautions ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 9 .
– Wrap a clean cloth around the connection before opening the
fuel system. Then release pressure by carefully pulling hose
off connection.
– Pull fuel supply line -arrow- off high-pressure pump.
AG. Volkswagen AG d
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– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable
h re
hole
-adapter- to fuel supply line -1-. Connect other adapter -3- from
spec
K-Jetronic pressure tester - V.A.G 1318- to open connection
es, in part or in w
on high pressure pump.
t to the co
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4. Fuel pump 263

Note
The K-Jetronic pressure tester - V.A.G 1318- must be inserted as

an intermediate element into the fuel supply line.
– Connect ⇒ Vehicle diagnostic tester and carry out Test elec-

tric fuel pump(s) .
Note
The fuel pump will be activated for 30 seconds.
– Run fuel pumps until highest fuel pressure has built up.
• Specification: at least 3.5 bar AG. Volkswagen AG d
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If specification is not obtained by
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Check threaded connection between pressure gauge and fueluline
thor eo
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for leaks. ss a c
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Check pressure tester for leaks.

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Check fuel lines and their connections for leaks.
erm
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Check whether fuel filter is blocked.
wit
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Check fuel delivery rate of fuel system pressurisation pump - G6-
hole
⇒ page 266 .
spec
es, in part or in w
t to the co
Note
rrectness of i
Check fuel system for leaks.
l purpos
4.4 Checking delivery pressure of fuel sys‐
nf
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tem pressurisation pump - G6-
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♦ Pressure gauge - VAS 6550-

Test conditions
• Fuses must be OK.
• Battery voltage at least 12 V
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• Fuel filter and fuel lines must not be blocked.
Sequence of operations AG. Volkswagen AG d
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– Remove front left underbodybcladding
yV
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t to the co
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4. Fuel pump 265

– Press the circlip to release the fuel line and then detach the
fuel supply line -1-.
– Connect pressure tester - VAS 6550- with cables -VAS
6550/1- and -VAS 6550/2- to open ends of fuel supply line
-1-.
– Switch on pressure tester - VAS 6550- by pressingolkOn/Off
swa
ge es n
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button. ed
by
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or
– Open shut-off taps “A” and “B” of pressureau
th tester and close or
ac
shut-off tap “C”. ss
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– Start engine and allow it to run at idling speed. du
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– Read pressure shown by pressure tester - VAS 6550- . Spec‐
erm
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ification: at least 0.5 bar.
ot p
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– Place pressure tester - VAS 6550- onto windscreen so that it
h re
hole
can be read from inside vehicle.
spec
es, in part or in w
– Increase idling speed to 2500 rpm and read the pressure
t to the co
shown on the pressure tester - VAS 6550- . Specification: at
least 0.25 bar.
rrectness of i
– If the delivery pressure temporarily drops, renew fuel delivery
unit ⇒ page 257 .
l purpos
– If specifications are obtained, renew fuel filter to ensure the

fuel filter is not blocked.
nf
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or
– Check fuel pump delivery rate ⇒ page 266 .
m
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4.5 Checking fuel delivery rate of fuel sys‐

or
thi
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sd
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tem pressurisation pump - G6-

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♦ Torque wrench - V.A.G 1331- ht. rig
rig ht
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♦ Pressure gauge - VAS 6550-

Test conditions
• Battery voltage at least 12 V
• Fuel filter and fuel lines must not be blocked.
– Pull out connector on supplementary fuel pump - V393- .
– Remove front left underbody cladding -arrow-. AG. Volkswagen AG d
agen oes
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spec
t to the co
– Press the circlip to release the fuel line and then detach the
fuel supply line -1-.
rrectne
– Connect pressure gauge pipe -VAS 6550/1- to the fuel supply
line -1-.
ss o
– Place open end of line in the measuring tank.
cial p
f inform
mer
tric fuel pump(s) .
atio
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Note
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t.
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Cop py
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gh
– When fuel stops flowing, read amount of fuel delivered as in‐
ht
pyri by
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o
dicated on measuring container. Specified amount at least
c by lksw
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1000 ml/30 sec. Prote AG.
If specification is not obtained

– Check voltage supply ⇒ page 267 and current draw
⇒ page 269 of fuel pump.
4.6 Checking voltage supply of fuel system

pressurisation pump - G6-
4. Fuel pump 267

♦ Hand multimeter - V.A.G 1526 E-

AG. Volkswagen AG d
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♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
rrectness of i
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Test conditions
by lksw
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• The battery voltage must be at least 12 V; if necessary connect
a battery charger.
– Switch on ignition. The fuel pump must run audibly for about
2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Pull connector off fuel delivery unit flange.
Note
The fuel tank has to be lowered in order to be able to remove the

connector from the flange of the fuel pump unit ⇒ page 252
– Remove cover of fuel delivery unit.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐
tween connector and flange.

– Connect hand-held multimeter - V.A.G 1526D- to contacts

-1- and -5- of adapter.
– Connect ⇒ Vehicle diagnostic
n AG.tester
Volkswaand carry
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wage es n
tric fuel pump(s)
Vo .
lks ot g
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Note
ss
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ab
ility
– Read voltage value on hand-held multimeter - V.A.G 1526D- :
ot p
wit
Specification = battery voltage.
is n
h re
ole,
If no voltage is present:
spec
– Check activation of fuel pump relay and wiring for open circuit
t to the co
and short circuit ⇒ Vehicle diagnostic tester.
Voltage supply OK:
rrectne
– Remove fuel delivery unit ⇒ page 257 .
ss
– Check that the electrical lines between flange and fuel pump
o
cial p
f
are connected and have continuity.
inform
mer
If no open circuit can be found:
atio
om
– Renew fuel delivery unit ⇒ page 257 .
n
c
i
or
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te
sd
a
4.7 Checking current draw of fuel system

iv
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pr
cum
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fo
pressurisation pump - G6-

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♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
4. Fuel pump 269

Note
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason,
ensure that the battery voltage is at least 12 V whilst checking,
and that the diesel fuel temperature in the fuel tank does not fall
to nearly the freezing point.
Test conditions n AG. Volkswagen AG do

lkswage es n
• Diesel fuel temperature aboved by V 10 °C
o ot g
ua
ran
ir se tee
• Fuses must be OK. uth o
or
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ss
• The battery voltage must be at least 12 V; if necessary connect
ce
le
a battery charger.
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
Note
t to the co
The fuel tank has to be lowered in order to be able to remove the
rrectne
connector from the flange of the fuel pump unit ⇒ page 252
s
– Remove cover of fuel delivery unit.
s o
cial p
f
– Pull connector off fuel delivery unit flange.
inform
mer
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

atio
m
connector and fuel delivery unit.

o
n
c
i
or
– Connect pick-up clamp -A- to red terminal with lettering “pick-

thi
te
sd
a
up clamp” for test instrument adapter/DSO (5-pin) - VAS

iv
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pr
5565- .
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Note
t
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cted
Pickup clamp of hand-held multimeter - V.A.G 1715- can also be
agen
Prote AG.
connected to red terminal with lettering “pickup clamp” of test in‐
strument adapter/DSO (5-pin) - VAS 5565- .

tric fuel pump(s) .
Note
– Read current draw on hand-held multimeter - V.A.G 1526D- .

Specification: max. 7.5 amps.
– If the measured value is not within specifications:
– Renew fuel delivery unit ⇒ page 257 .

5 Accelerator pedal
⇒ “5.1 Functional check”, page 271
⇒ “5.2 Assembly overview - accelerator mechanism”, page 271
5.1 Functional check

With the EPC system, the throttle valve is not operated by a cable
from the accelerator There is no mechanical connection between
the accelerator and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit .
The throttle valve is actuated by a servomotor (throttle valve po‐
sitioner) in the throttle valve module over the full range of engine
speeds and load conditions.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit .
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender .
This means that the throttle valve can already be completely open
even though the accelerator is only depressed half way. This has
the advantage of preventing throttling losses at the throttle valve.
After evaluating the torque requirements of the various compo‐
nents (e.g. air conditioning system, automatic gearbox, ABS/ agen AG. Volkswagen AG do
ESP, etc.), the engine control unit calculates the optimal throttle
olks
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valve opening angle for the respective situation. se
d b ua
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ri tee
ho
This also results in significantly improved consumption
ut and ex‐ or
ac
sa
haust emission values under certain load conditions.
s
ce
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un
pt
“EPC” is a system comprising all components which contribute to
an
d
itte
y li
determining, controlling or monitoring the position of the throttle
rm
ab
valve (e.g. accelerator position sender , throttle valve control
pe
ility
module , EPC warning lamp , engine control unit ).
ot
wit
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h re
5.2 Assembly overview - accelerator mechanism
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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5. Accelerator pedal 271

1 - Mounting bracket
❑ Removing and instal‐
ling: ⇒ Rep. gr. 46 ;
AG. Volkswagen AG d
Brake system; Remov‐ ksw
agen oes
not
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ing and installing
by V bear‐
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ing bracket
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2 - Connector
ss
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❑ 6-pin
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pt
du
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3 - Nut
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ab
❑ 10 Nm
ility
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4 - Acceleration pedal position
h re
sender - G79-
hole
spec
❑ Not adjustable.
es, in part or in w
t to the co
rrectness of i
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ate
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21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 273
⇒ “1.2 Assembly overview – connecting pipes (bi-turbo)”,
page 282
⇒ “1.3 Removing and installing turbocharger”, page 284
⇒ “1.4 Removing and installing exhaust manifold gasket (bi-tur‐
bo)”, page 311
⇒ “1.5 Removing and installing compressor housing and turbine
housing (bi-turbo)”, page 319
⇒ “1.6 Checking vacuum unit for turbocharger”, page 321
⇒ “1.7 Renewing vacuum unit for turbocharger”, page 327
⇒ “1.8 Removing and installing connecting pipes (bi-turbo)”, page
336
1.1 Assembly overview - turbocharger

⇒ “1.1.1 Assembly overview - turbocharger, single turbo”,
page 273
⇒ “1.1.2 Assembly overview - turbocharger, bi-turbo”, page 278
⇒ “1.1.3 Assembly overview - turbocharger, bi-turbo dismantled”,
page 281
1.1.1 Assembly overview - turbocharger, single turbo

G. Volkswage A n AG d
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Note rise nte
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♦ Sealed bolts and nuts must not be loosened.
s
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pt
du
♦ All hose connections are secured. an

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♦ Charge air system must be free of leaks. ility
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♦ Renew self-locking nuts.

wit
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hole
♦ Before screwing on oil supply line, fill turbocharger at connection with engine oil.
spec
es, in part or in w
♦ After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to
t to the co
turbocharger.
rrectness of i
l purpos
nform
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at
om
ion
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or
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do
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1. Exhaust turbocharger 273

1 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler.
2 - Nut
❑ 20 Nm
3 - Seal
olkswagen AG
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4 - Seal ksw
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5 - Connector aut ra
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6 - Exhaust gas temperature
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sender 1 - G235-
an
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❑ Only fitted on 84, 100
erm
ab
ility
and 103 kW engines.
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❑ Grease thread of sender
h re
using high-temperature
hole
spec
paste ⇒ Electronic
es, in part or in w
t to the co
KA) .
❑ Sender must not be bent
rrectness of i
when removing and in‐
stalling.
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❑ Sender must not contact

any other component on
nf
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installation. orm
❑ 45 Nm
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7 - Plug
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❑ Only fitted in 62 and 75

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❑ Grease thread of plug

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Parts Catalogue (ET‐ p by
co Vo
KA) .
by lksw
cted agen
Prote AG.
❑ 45 Nm
8 - Exhaust turbocharger
❑ Must only be renewed together with exhaust manifold and position sender for charge pressure positioner
- G581- .
❑ Note tightening sequence and installation procedure ⇒ page 276 .
9 - Nut
❑ Observe tightening sequence and procedure ⇒ page 276 .
❑ 25 Nm
10 - Screw-type clamp
❑ 5.5 Nm
11 - Intake hose
❑ Fitting position ⇒ page 276
12 - Pipe line
❑ Do not separate plug-in connection for hose and pipe if possible.
❑ Note procedure for separating and connecting pressure hose ⇒ Item 13 (page 275) under all circum‐
stances ⇒ page 347 .
274 Rep. gr.21 - Turbocharging/supercharging

13 - Connection hose AG. Volkswagen AG d

agen oes
ksw
❑ Do not separate plug-in connection for hose and pipe by
V if possible.
o l not
gu
ara
ed
❑ Note procedure for separating and connectinghopiperis ⇒ Item 12 (page 274) under all circumstances nte
eo
⇒ page 347 . aut ra
c
ss
❑ Note installation position of connecting hose ⇒ page 277 .
ce
le
un
pt
an
d
itte
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erm
ab
❑ 5.5 Nm
ility
ot p
wit
15 - Bolt
is n
h re
ole,
❑ 10 Nm
spec
16 - Pulsation damper
t to the co
17 - Seal
rrectne
18 - Support ring
s
s o
cial p
f
❑ Installation position in pulsation damper ⇒ page 277 .
inform
mer
19 - Support
atio
m
❑ When installing turbocharger, support must be released on crankcase and turbocharger.

o
n
c
i
or
n thi
20 - Bolt
te
sd
iva
o
❑ 20 Nm
pr
cum
r
fo
en
ng
21 - Seal
t.
yi Co
op py
❑ Renew after removal t. C rig
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pyri by
22 - Oil return pipe
o Vo
by c lksw
cted agen
Prote
❑ After installing oil supply pipe, ensure that it is not blocked.
AG.
23 - Bolt
❑ 15 Nm
❑ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362- are recommended for installation of spring-
type clips.
25 - Oil return hose
❑ After installing oil return hose, ensure that it is not blocked.
26 - Bolt
❑ 23 Nm
27 - Heat shield
Note
♦ One of two different heat shields

are fitted and this depends on
equipment installed.
♦ Only one is available as a re‐
placement part.
28 - Vacuum unit with regulating flap potentiometer - G584-

29 - Bolt
❑ 25 Nm + 90°
❑ 8 Nm

31 - Seal
32 - Banjo bolt
❑ Renew after removal agen
AG. Volkswagen AG d
oes
lksw not
❑ 30 Nm d by Vo gu
ara
rise nte
33 - Sealing ring utho eo
ra
a
❑ Renew after removal ss c
ce
le
un
pt
34 - Oil supply line
an
d
itte
y li
❑ Before installing oil supply line, ensure that it is not blocked.
erm
ab
ility
ot p
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
wit
is n
h re
35 - Sealing ring
ole,
spec
t to the co
36 - Bolt
❑ 10 Nm
rrectne
38 - Union nut
ss o
❑ Counterhold connection using open-end spanner AF14 - T10461-
cial p
f inform
❑ 22 Nm
mer
atio
om
n
c
i
or
n
Tightening sequence and procedure
thi
te
sd
iva
o
• Support ⇒ Item 19 (page 275) must be released on crankcase
pr
cum
r
fo
and turbocharger.
en
ng
t.
yi Co
op
♦ Position turbocharger ⇒ Item 8 (page 274) on studs on cylinder C py
t. rig
head.
gh ht
pyri by
Vo
co lksw
by
♦ Only screw bolt by hand into turbocharger. Prote
cted AG.
agen
♦ Tighten nuts -1- to -8- to 25 Nm in specified sequence. Then,

tighten nuts to 25 Nm again in the specified tightening se‐
quence.
♦ Tighten bolt ⇒ Item 29 (page 275) .
Installation position of intake hose at turbocharger

– Fit connecting hose in such a way that the “extension” -2- of
the connecting hose is in contact with the corner of the name‐
plate -2-.

Installation position of connecting hose

– Install connecting hose in such a way that marking -1- on con‐
necting hose is opposite marking -2- on pulsation damper.
Installation position of O-ring and seals in pulsation

agen
AGdamper
. Volkswagen AG
doe
ksw s no
Vol t gu
d by ara
e nte
1 - Shock absorber ris
tho eo
au ra
❑ With grooves ss c
ce
e
nl
2 - O-ring
pt
du
an
itte
y li
3 - Sealing ring
erm
ab
ility
ot p
❑ With spring
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.1.2 Assembly overview - turbocharger, bi-turbo

agen oes
olksw not
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♦ Sealed bolts and nuts must inot sed be loosened.
b ara
nte
or eo
th
♦ All hose connections are
s ausecured. ra
c
s
♦ Before screwing on oil supply line, fill turbocharger at connection with engine oil.
ce
le
un
pt
an
d
itte
♦ After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to
y li
rm
ab
turbocharger.
pe
ility
ot
wit
, is n
h re
hole
1 - Exhaust manifold gasket
spec
es, in part or in w
t to the co
2 - O-ring
rrectness of i
❑ Coat new O-ring thinly
l purpos
with lithium grease ⇒

Electronic parts cata‐
logue (ETKA) .
nform
ercia
3 - Lines
m
a
com
tio
❑ To charge pressure
n in
r
sender 2 - G447-
te o
thi
s
iva
do
4 - Sealing ring
r
rp
cum
fo

en
ng
t.
yi Co
❑ Qty. 2 ht. Cop py
rig
rig ht
5 - Banjo bolt py by
co Vo
by lksw
❑ 25 Nm
cted agen
Prote AG.
6 - Exhaust turbocharger
❑ Renewing vacuum unit
for turbocharger
⇒ page 327
❑ Vacuum unit with regu‐
lating flap potentiometer
- G584- ⇒ page 327
⇒ page 298
7 - Nut
❑ Tightening sequence
and procedure
⇒ page 280 .
❑ 25 Nm
8 - Seal
9 - Oil return line
❑ Can only be renewed with turbocharger removed.
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 11 Nm

12 - Bolt
❑ 60 Nm
• Adhere to assembly sequence.
♦ Bolt must be released on crankcase.
♦ Position turbocharger ⇒ Item 6 (page 278) on studs on cylinder head.
♦ Only screw bolt ⇒ Item 23 (page 279) by hand into turbocharger.
♦ Tighten turbocharger ⇒ Item 6 (page 278) bolts in specified sequence.
♦ Tighten bolt.
13 - Clamp
❑ After removal, oil return lines ⇒ Item 9 (page 278) and ⇒ Item 15 (page 279) must be renewed.
14 - Union
❑ With captive seal
❑ If union is released, it must be renewed.
❑ 75 Nm
15 - Oil return line
❑ Can only be renewed with turbocharger removed. AG. Volkswagen AG d
agen oes
❑ 60 Nm olksw not
yV gu b ara
ed n
16 - Support tho
ris tee
or
u
❑ When installing turbocharger, support must
ss
a
be released on crankcase and turbocharger. ac
ce
le
un
17 - Bolt
pt
an
d
itte
y li
❑ 9 Nm
erm
ab
ility
ot p
18 - Banjo bolt
wit
is n
❑ 40 Nm
h re
ole,
spec
19 - Oil supply line
t to the co
❑ Can only be renewed with turbocharger removed.
20 - Bolt
rrectne
❑ 9 Nm
21 - Banjo bolt
ss
❑ 30 Nm
o
cial p
f inform
22 - Twin-lip oil seal
mer

atio
om
n
c
23 - Bolt
i
or
n thi
te
sd

iva
o
pr
cum
r
• Adhere to assembly sequence.

fo
en
ng
t.
yi Co
♦ Bolt ⇒ Item 12 (page 279) must be released on crankcase. Cop py
t. rig
gh ht
yri
♦ Position turbocharger ⇒ Item 6 (page 278) on studs on cylinder head. p by
co Vo
by lksw
cted agen
♦ Only screw bolt by hand into turbocharger. Prote AG.
♦ Tighten turbocharger ⇒ Item 6 (page 278) bolts in specified sequence.

♦ Tighten bolt.
❑ 25 Nm +90°

California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ➤ , Transporter n A20
G. V...
olkswagen AG
wage does
4-cylinder diesel engine (2.0 l engine, common rail) - Editiony V08.2016
olks not
g b ua
ed ran
ris tee
24 - Washer tho
or
au ac
ss
25 - Banjo bolt
ce
le
un
pt
❑ 25 Nm
an
d
itte
y li
rm
ab
26 - Bolt
pe
ility
❑ 9 Nm
ot
wit
, is n
h re
27 - Heat shield
hole
spec
es, in part or in w
28 - Exhaust gas temperature sender 1 - G235-
t to the co
❑ Grease thread of sender using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ Must not be bent or twisted.
rrectness of i
❑ Must not contact any other component when installed.
l purpos
❑ 45 Nm
nform
ercia
Tightening sequence and installation procedure
m
a
com
tio
• Support ⇒ Item 16 (page 279) must be released on crankcase
n in
r
and turbocharger.
te o
thi
s
iva
do
♦ Position turbocharger on studs on cylinder head.
r
rp
cum
fo
♦ Only screw bolt ⇒ Item 23 (page 279) by hand into turbo‐
en
ng
t.
yi Co
charger. t. Cop py
rig
gh ht
♦ Tighten nuts -1- to -9- to 25 Nm in specified sequence. Then, yri
p by
o Vo
tighten nuts to 25 Nm again in the specified tightening se‐
c by lksw
cted agen
quence.
Prote AG.

Installation position of connecting hose at turbocharger

– Fit connecting hose so that “rib” -1- of connecting hose aligns
with middle of data sticker -2-.

1.1.3 Assembly overview - turbocharger, bi-turbo dismantled
1 - Bolt
❑ 9 Nm
3 - Bolt
❑ 8 Nm
4 - Compressor bypass
5 - O-ring
6 - Bypass valve
❑ 2 O-rings AG. Volkswagen AG d
agen oes
7 - Bolt olksw not
byV gu
ara
d
❑ 8 Nm orise nte
eo
h
ut ra
8 - Heat shield ss a c
ce
e
nl
9 - O-ring
pt
du
an
itte
y li
10 - ASSY - high-pressure tur‐
erm
ab
bocharger
ility
ot p
wit
, is n
11 - Seal ⇒ page 319
h re
hole
❑ Between output stages.
spec
es, in part or in w
12 - Locking plate
t to the co
13 - Nut
❑ 8 Nm
rrectness of i
14 - Nut
l purpos
❑ 8 Nm
nform
ercia
15 - Nut
m
❑ On flange between the

at
om
io
stages.
n
c
in t
or
❑ 24 Nm
his
ate
do
riv
❑ Tightening sequence:
p
cum
or
diagonal sequence
f
en
ng
t.
yi Co
16 - Locking plate ht. Cop py
rig
rig ht
17 - Nut py by
co Vo
by lksw
❑ 8 Nm
cted agen
Prote AG.

19 - ASSY - low-pressure turbocharger
20 - Vacuum unit for wastegate
21 - Bolt
❑ 14 Nm

22 - Oil return line

23 - Seal n AG. Volkswagen AG do
lkswage es n
24 - Bolt d byV
o ot g
ua
ran
❑ 8 Nm ir se tee
tho
u or
a ac
25 - O-ring ss
ce
e
nl
pt
26 - Connecting pipe
du
an
itte
y li
erm
27 - Heat shield
ab
ility
ot p
28 - Clamp
wit
, is n
h re
29 - Plug & seal
hole
spec
es, in part or in w
t to the co
1.2 Assembly overview – connecting pipes (bi-turbo)
rrectness of i
l purpos
1 - O-ring
nform
ercia
❑ Coat new O-ring thinly

with lithium grease ⇒
m
at
Electronic parts cata‐
om
ion
logue (ETKA) .
c
in t
or
his
te
2 - Bolt
a
do
priv
❑ 8 Nm
um
for
en
ng
t.
yi
3 - Connecting pipes
Co
Cop py
. rig
t
gh ht
yri by
⇒ page 336 cop Vo
by lksw
cted agen
Prote
4 - Thrust ring
AG.
❑ Do not separate from

pulsation damper
❑ Not sold separately.
❑ Included in
5 - O-ring
❑ Not sold separately.
❑ Use seal set ⇒ Electron‐
ic parts catalogue (ET‐
KA)
❑ Note installation posi‐
tion of connecting hose
⇒ page 283 .
7 - Bolt
❑ 8 Nm
8 - Holder
9 - Charge pressure sender 2 -
G447-
❑ Must be adapted after installation ⇒ Vehicle diagnostic tester
10 - Bolt
❑ 9 Nm

11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 8 Nm
13 - Sealing ring
14 - Banjo bolt
❑ 25 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
15 - Clamp d byV ua
ran
ir se
❑ Replaced by a screw-type clip in the repairuth set
o tee
or
a ac
16 - Insulated hose ss
ce
e
nl
pt
❑ Renew after removal du
an
itte
y li
17 - Connecting/sealing pipe
erm
ab
ility
ot p
wit
, is n
h re
18 - Bolt
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
19 - Holder
20 - Nut
rrectness of i
❑ Tighten with ratchet wrench 13 mm - T10384- .
l purpos
❑ 20 Nm
nf
ercia
or
Installation position of connecting hose
m
m
atio
m

o
n in
or c
necting hose is opposite marking -2- on pulsation damper.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.3 Removing and installing turbocharger

⇒ “1.3.1 Removing and installing turbocharger, single turbo”,
page 284
⇒ “1.3.2 Removing and installing turbocharger, single turbo, all-
wheel drive vehicles”, page 290
⇒ “1.3.3 Removing and installing turbocharger, bi-turbo”,
page 298
⇒ “1.3.4 Removing and installing turbocharger, bi-turbo, all-wheel
drive vehicles”, page 304
1.3.1 Removing and installing turbocharger, single turbo
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
1331- agen oes
olksw not
byV gu
ara
♦ Torque wrench - V.A.Gris ed
nte
1332- aut
ho eo
ra
ss c
ce
e
nl
6340-
pt
du
an
itte
y li
♦ Open-end spanner, 14 mm
erm
ab
- T10461-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
must be carried out:
♦ Check air filter container, air filter element and intake ho‐
ses for dirt.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
Observe rules for cleanliness ⇒ page 10 .
– Screw nuts -2- off connecting pipe -3-. Take care not damage
exhaust temperature sender 1 - G235- -1- in the process.
– Unscrew bolts for connection pipe -3- on exhaust gas recircu‐
lation cooler.
– Remove connecting pipe -3-.
AG. Volkswagen AG d
agen oes
– Unscrew bolts -1- and remove
Vol
ksw heat shield -2-. not
gu
y
db ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
♦ There are two different heat shields.

♦ I Large heat shield
♦ II Small heat shield
– Unscrew nuts at top -arrows- from turbocharger.
Caution
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Open screw-type clip -1-ris far enough to enable removal of
ed
nte
pressure hose. aut
ho eo
ra
ss c
ce
e
nl
pt
du
an
– Detach vacuum hose -3-.

itte
y li
erm
ab
– Pull connector -2- and hose -3- out of the mounting -arrow-.
ility
ot p
wit
, is n
– Loosen screw-type clip -4-.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Lift retaining clip (not shown in illustration), pull pressure hose
rrectne
-1- off charge air cooler -arrow- and remove.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Release and detach connector -arrow- of exhaust temperature
p by
o Vo
by c lksw
sender 1 - G235- . Then, lay wiring harness to one side. Prote
cted AG.
agen
– Unscrew union nut -4- and banjo bolt -6-.

– Remove nut -8- and remove oil supply line -5-.

– Remove nuts -arrows-. The nuts cannot be seen from below

or above. Use a mirror if necessary.
Note
If the oil supply line on the turbocharger is loosened, counterhold

the connection using open-end spanner AF14 - T10461- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Unscrew exhaust
s temperature sender 1 - G235- -3-.
s c
ce
le
un
– Remove nut -7-.
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
It may not be possible to remove the spring-type clip due to its
hole
spec
location and the restricted space. In this case, remove the rear
es, in part or in w
torque reaction support ⇒ page 34 .
t to the co
rrectness of i
l purpos
– Remove spring-type clip -3- with hose clip pliers - VAS 6340- .
nform
mercia
– Cover anti-roll bar with a cloth or similar to avoid damage to a

com
tio
paintwork.
n in
r
te o
thi
– Remove turbocharger -1-.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Once turbocharger has been removed, bolt -2- must be re‐

leased from bracket -1- for reinstalling.
Installing
♦ Apply engine oil to inside of oil return hose to facilitate instal‐
lation if rear torque reaction support is fitted.
♦ Observe instructions for hose connections with screw-type
clips ⇒ page 347 .
♦ Renew banjo bolt of turbocharger support as well as seals and
gaskets.

Bolt -2- must be released from bracket -1- for reinstalling.
– Place turbocharger -1- on studs and push oil return hose -4- n AG. Volkswagen AG do
onto oil return pipe. lkswage es n
Vo ot gu
by ara
– Screw in bolt -2- hand-tight. ed nte
oris eo
th
au ra
c
ss
Caution
ce
e
nl
pt
du
an
itte
y li
• Note tightening sequence and procedure when bolting
erm
ab
turbocharger on ⇒ page 276 .
ility
ot p
wit
, is n
h re
hole
– Install rear torque counteracting support ⇒ page 34
spec
es, in part or in w
t to the co
Torque settings
rrectness of i
♦ ⇒ “1.1.1 Assembly overview - turbocharger, single turbo”,
page 273
l purpos
nform
ercia

m
at
om
io
n
c
in t
r

o
his
ate
do
priv
1.3.2 Removing and installing turbocharger,

um
for
en
ng
t.
yi
single turbo, all-wheel drive vehicles
Co
Cop py
t. rig
gh ht
yri
Special tools and workshop equipment required p by
co Vo
by lksw
cted agen
♦ Torque wrench - V.A.G 1410- Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
♦ Open-end spanner, 14 mm - T10461-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Caution
t.
yi Co
Cop py
ht. rig
If a mechanical fault is found on the turbocharger, e.g. a de‐
rig ht
py by
o Vo
stroyed compressor impeller, just renewing the turbocharger is by c lksw
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not enough. To avoid subsequent damage, the following work Prote AG.
must be carried out:
♦ Check air filter container, air filter element and intake ho‐
ses for dirt.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Before the “single turbo” can be removed, the following parts must
be removed:
♦ Complete drive shaft on the right
♦ Rear torque reaction support
♦ The particulate filter
♦ Catalytic converter
♦ Wiring bracket on subframe
♦ Front propshaft tube
♦ Front heat shield

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Assembly overview - charge-air hose connections ⇒ page 347
pe
ility
ot
wit
, is n
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hole
spec
– Unscrew bolts for connection pipe -3- on exhaust gas recircu‐
es, in part or in w
t to the co
lation cooler.
– Remove connecting pipe -3-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
– Unscrew bolts -1- and remove heat shield -2-.

te o
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t. rig
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co lksw
by
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Prote AG.
Note
♦ There are two different heat shields.

♦ I Large heat shield
♦ II Small heat shield

– Unscrew nuts at top -arrows- from turbocharger.
Caution
Removing screw-type clips ⇒ page 347 . agen
AG. Volkswagen AG d
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rm
ab
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ility
pressure hose. ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Pull connector -2- and hose -3- out of the mounting -arrow-.
– Loosen screw-type clip -4-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lift retaining clamp (not visible in picture) then pull the delivery
hose -1- off the charge air cooler -arrow- and remove.
AG. Volkswagen AG d
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aut ra
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erm
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ility
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sender 1 - G235- . Then, lay wiring harness to one side.
wit
, is n
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hole
spec
– Remove complete right-hand drive shaft ⇒ Running gear,
es, in part or in w
t to the co
axles, steering; Rep. gr. 40 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Unscrew nuts for heat shield -arrow-.

o
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or c
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te
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t.
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t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew bolts -arrows- from front intermediate bearing and

hold propshaft by hand. At the same time, a 2nd mechanic
removes the heat shield.
– Bolt on intermediate bearing hand-tight.

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Vol,ksCaravelle
wagen AG 2010 ➤ , Multivan 2010 ➤ , Transporter 20 ...
does
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V 4-cylinder diesel engine (2.0 gluengine, common rail) - Edition 08.2016
ol not
by ara
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– Unscrew bolt -1-aufrom
th support mounting -3-. e or
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ss
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pt
an
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rm
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pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Unscrew bolts -2- and bolt -3- and remove rear torque reaction
do
r
rp
c
support -1-.
um
fo
en
ng
t.
yi
– Remove front propshaft tube ⇒ Rep. gr. 39 ; Final drive; As‐
Co
op py
sembly overview - final drive . t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew bolts -1- and -2- and remove gearbox carrier -3- from
rear torque reaction support and from bevel box.
– Unscrew bolts -1- and remove catalytic converter bracket -2-.

– Remove all lines/wires at the bracket -arrow-. Then remove

bracket from subframe.
– Unscrew union nut -4- and banjo bolt -6-.

– Remove nut -8- and remove oil supply line -5-.
wage e
– Remove nuts -arrows-. The nuts yV
cannot
olks be seen from belows not g
or above. Use a mirror if necessary.
isedb ua
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Note
ce
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un
pt
an
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If the oil supply line on the turbocharger is loosened, counterhold

rm
ab
the connection using open-end spanner AF14 - T10461- .

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew exhaust temperature sender 1 - G235- -3-.

rrectness of i
– Remove nut -7-.

l purpos
Note
nform
mercia
It may not be possible to remove the spring-type clip due to its

com
tio
location and the restricted space. In this case, remove the rear
n in
r
te o
torque reaction support ⇒ page 34 .

thi
s
iva
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en
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t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Remove spring-type clip -3- with hose clip pliers - VAS 6340- .
– Remove turbocharger -1-.
– Cover anti-roll bar -2- with a cloth or similar to avoid damage

to paintwork.
– Place turbocharger -1- “upside down” and guide to the left.
– Remove turbocharger -1- between bevel box and subframe.
– Once turbocharger has been removed, bolt -2- must be re‐

leased from bracket -1- for reinstalling.
Installing
wage es n
Install in reverse order of removal, observing the
y V following:
olks ot g
ua
b
ed ran
♦ Apply engine oil to inside of oil returnthhose
or
is to facilitate instal‐ tee
lation if rear torque reaction supports a is fitted.
u or
ac
s ce
♦ Observe instructions for hose connections with screw-type
e
nl
pt
du
clips ⇒ page 347 .

an
itte
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erm
ab
♦ Renew banjo bolt of turbocharger support as well as seals and

ility
ot p
gaskets.
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
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or c
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te
sd
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place turbocharger -1- on studs and push oil return hose -4-
onto oil return pipe.
– Screw in bolt -2- hand-tight.
Caution

– Install rear torque counteracting support ⇒ page 34

Torque settings
olkswagen AG
♦ ⇒ “1.1.1 Assembly overview - turbocharger, single turbo”, swagen AG. V does
page 273 by
Vol
k not
gu
d ara
se nte
♦ ⇒ “3.1.2 Assembly overview - exhaust gas recirculation
ho
ri cooler, eo
single turbo engine ”, page 484 aut ra
s s c
ce
le

un
pt
an
d
itte
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rm
ab
pe
ility
♦ Drive shafts; Assembly overview - drive shafts ⇒ Running
ot
wit
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
, is n
h re
overview - drive shaft
hole
spec
es, in part or in w
t to the co
rrectness of i
1.3.3 Removing and installing turbocharger, bi-turbo
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.


equipment required
1331-
1332- lkswage es n
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yV ua
♦ Torque wrench - V.A.G ir se
d b ran
tee
1410- utho
or
a ac
ss
ce
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VAS 6122-
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Separate electrical connector -arrow- of exhaust gas temper‐
ature sender 1 - G235- .
– Move wiring harness clear.
– Remove connecting pipe ⇒ page 282
Note
♦ Seal open lines and hoses immediately with bungs from en‐
gine bung set - VAS 6122- .

– Unscrew bolt -2- and remove from clamp -1-.

– Loosen particulate filter -3-.
– Unscrew nuts -arrows- above and to right of turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Unscrew nuts -arrows- above and to left of turbocharger.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Pull out lines -2, 3, 4- from mounting of intake hose -1-.

i
o
pr
cum
r
fo
en
ng

t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Remove right drive shaft completely ⇒ Running gear, axles,
drive shaft .

– Unscrew bolts -2- and -3-

– Remove rear torque reaction support -1-.
AG. Volkswagen AG d
agen oes
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ris nte
o
– Unscrew
aut
h bolt -2- of oil supply line -3-. eo
ra
ss c
– Place a cloth underneath and collect any escaping oil.
ce
e
nl
pt
du
an

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove all lines/wires at the bracket -arrow-.

– Then remove bracket from subframe.
– Pull off hose -1- from vacuum unit for wastegate -2-.
. Volkswagen AG
gen AG d
– Separate electrical connectorVol
-1-
ksw
a
of vacuum unit withoeregulat‐
s no
t gu
ing flap potentiometere-d bG584- .
y ara
is nte
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– Pull off vacuum hose
au
th -2- of vacuum unit with regulating flap ra
potentiometer -sG584- -3-.
s c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew bottom right nuts -arrow- from turbocharger.

– Unscrew bottom left nuts -arrow- from turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew union nut -4- of oil return line -3-, counterholding on
wit
, is n
connection -5- when doing so.
h re
hole
spec
es, in part or in w
Caution
t to the co
• Do not separate oil return line at clamp
⇒ Item 13 (page 279) .
rrectness of i
• If the oil return line is separated at the hose clip
l purpos
⇒ Item 13 (page 279) or if it is damaged, the hoses of the

oil return line must be renewed.
nform
mercia
at
– Remove bolt -1- from bracket -2-.
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Cover anti-roll bar with a cloth or similar to avoid damage to
lksw
cted agen
Prote
paintwork.
AG.
Caution
Risk of damage when removing and installing turbocharger.

• Oil supply line must not be kinked when removing and in‐
stalling.
• Check oil supply line for damage after removing (kinks in
hose). Oil supply line must be renewed if damaged.
• When doing this, ensure that no pressure is exerted on the
linkage of vacuum unit.
• Do not hold onto control rods of vacuum unit when re‐
moving the turbocharger.
– Remove turbocharger, tilt to rear and remove via subframe

and anti-roll bar.

Installing
– Clean sealing surfaces.
– Loosen bolt -2- from bracket -1- for reinstallation.
Volkswa AG. gen AG
agen does
olksw not
yV gu
Caution db ara
rise nte
tho eo
• When carrying thessturbocharger, always hold it au by the
ra
c
pipes and not by the actuator or the control rods of the
ce
e
nl
pt
vacuum unit.
du
an
itte
y li
• Check oil supply line for damage (kinks in hose) after in‐
erm
ab
ility
stalling turbocharger. Turbocharger must be removed
ot p
wit
again and oil supply line must be renewed if damaged.
, is n
h re
hole
• If the oil return line is separated at the clamp
spec
es, in part or in w
t to the co
oil return line ⇒ Item 9 (page 278) and
⇒ Item 15 (page 279) must be renewed.
rrectness of i
– Bring turbocharger into position.
l purpos
– Only screw bolt -1- into bracket -2- by hand.
nf
ercia
o
– Tighten turbocharger, observe tightening sequence
rm
m
atio
⇒ page 280 .
om
n in
c
– To tighten union nut, counterhold oil return line at connection;

or
thi
e
oil return line must not turn as well when tightening.

t
sd
iva
o
r
rp
cu
– Install connecting pipes ⇒ page 282 .

o
m
f
en
ng
t.
yi
• Observe installation position of connecting hose on turbo‐
Co
op py
charger ⇒ page 280
. C rig
ht ht
rig by
opy Vo
Torque settings by c lksw
cted agen
Prote AG.
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
1.3.4 Removing and installing turbocharger, bi-turbo, all-wheel drive vehicles


equipment required
1331-
1332-
1410-
VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Separate electrical connector -arrow- of exhaust gas temper‐

nform

mercia
– Then, lay wiring harness to one side.

a
com
tion in
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel

r
te o
thi
box .
s
iva
do
r
rp

um
fo
en
ng
t.
yi Co
Cop py
t.
Note
rig
gh ht
pyri by
Vo
co lksw
by
cted
♦ Seal open lines and hoses immediately with bungs from en‐
agen
Prote AG.
gine bung set - VAS 6122- .


– Loosen catalytic converter -3-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
– Pull out lines -2, 3, 4- from mounting of intake hose -1-.

ng
t.
yi Co
op py
– Loosen clamp -5-. t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Remove catalytic converter ⇒ page 479 .
– Remove right drive shaft completely ⇒ Running gear, axles,
drive shaft .
– Remove front propshaft tube ⇒ Rep. gr. 39 ; Final drive; As‐
sembly overview - final drive .


Volkswagen AG
– Remove gearbox carrier -3- from rear torque reactionswsupport
agen
AG. does
and from bevel box. by
Volk not
gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove holder for catalytic converter -2-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -2- and -3-.

– Remove rear torque reaction support -1-.

– Unscrew nuts for heat shield -arrow-.
– Unscrew bolts -arrows- from front intermediate bearing and

hold propshaft by hand. At the same time, a 2nd mechanic
removes the heat shield.
– Bolt on intermediate bearing again hand-tight.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Unscrew bolt -2- of oil supply line -3-.
ot p
wit
, is n
– Place a cloth underneath and collect any escaping oil.

h re
hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove all lines/wires at the bracket -arrow-.

– Then remove bracket from subframe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Pull off hose -1- from vacuum unit for wastegate -2-.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Separate electrical connector -1- of vacuum unit with regulat‐

t.
yi Co
op
ing flap potentiometer - G584- . C py
t. rig
gh ht
yri
– Pull off vacuum hose -2- of vacuum unit with regulating flap
p by
co Vo
by lksw
potentiometer - G584- -3-. Prote
cted AG.
agen

– Unscrew nuts -arrows- below and tonthe

wage
right
AG. Volkswof
agethe
n AGturbo‐
does
charger. y Volks not
gu b ara
ed
– Unscrew nuts -arrows- ribelow
s and to the left of the turbocharg‐ nte
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er. s au or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew union nut -4- of oil return line -3-, counterholding on
connection -5- when doing so.
rrectness of i
l purpos
Caution
• Do not separate oil return line at clamp
nform
ercia
⇒ Item 13 (page 279) .

m
at
om
i
• If the oil return line is separated at the hose clip
on
c
in t
or
his
e
oil return line must be renewed.

at
do
priv
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

paintwork.
Caution
Risk of damage when removing and installing turbocharger.

• Oil supply line must not be kinked when removing and in‐
stalling.
• Check oil supply line for damage after removing (kinks in
hose). Oil supply line must be renewed if damaged.
linkage of vacuum unit.
• Do not hold onto control rods of vacuum unit when re‐
moving the turbocharger.
– Remove turbocharger, tip towards the rear and remove via the
subframe.

Installing
– Loosen bolt -2- from bracket -1- for reinstallation. lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Caution auth or
ac
ss
ce
le
• When carrying the turbocharger, always hold it by the
un
pt
an
pipes and not by the actuator or the control rods of the
d
itte
y li
vacuum unit.
erm
ab
ility
• Check oil supply line for damage (kinks in hose) after in‐ ot p
wit
is n
stalling turbocharger. Turbocharger must be removed
h re
ole,
again and oil supply line must be renewed if damaged.
spec
• If the oil return line is separated at the clamp
t to the co
oil return line ⇒ Item 9 (page 278) and
⇒ Item 15 (page 279) must be renewed.
rrectnes
– Bring turbocharger into position.
s o
cial p
f inform
mer
atio
m
– Tighten turbocharger, observe tightening sequence

o
n
c
⇒ page 280 .
i
or
n thi
te
sd
a
– To tighten union nut, counterhold oil return line at connection;

iv
o
pr
c
oil return line must not turn as well when tightening.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
• Observe installation position of connecting hose on turbo‐
gh ht
pyri by
charger ⇒ page 280
co Vo
by lksw
cted agen
Prote AG.
Torque settings
1.4 Removing and installing exhaust mani‐

fold gasket (bi-turbo)
Note
♦ The turbocharger does not have to be removed completely to

remove and install the gasket.
♦ Use a commercially available stud extractor to remove the two
studs from the 1st cylinder.
♦ Note the installation location of the studs.


equipment required
1331-
1332-
1410-
VAS 6122-
AG. Volkswagen AG d
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In order to remove the gasket, the “bi-turbo” has to be »divided«

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in two. The upper part of the compressor pipes with the pulsation
Co
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damper must be removed upwards. The “bi-turbo” is removed t. C rig
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Removing Prote AG.

Note
♦ After lines and hoses have been removed, the open connec‐
tions are to be sealed immediately with a plug from the engine
bung set - VAS 6122- .

terior; Rep. gr. 66 ; Noise insulation .

olkswagen AG
en AG. V
California 2010 ➤ , Caravelle 2010 ➤o,lksMultivan
wag 2010 ➤ , Transporter
does
not 20 ...
V
4-cylinder diesel engine (2.0
ed byl engine, common rail) - Edition 08.2016
gu
ara
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– Release and detach connector -arrow- of exhaustss atemperature ra
c
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– Pull lines -2-, -3- and -4- out of mounting for intake hose -1-.
ss o
cial p
f
– Open screw-type clip -5- wide enough to enable removal of
inform
intake hose -1-.
mer
atio
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Cop py
t. rig
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pyri by
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Prote AG.

– Loosen particulate filter -3-.
All-wheel drive vehicles
– Disconnect catalytic converter.


♦ Front-wheel drive vehicles: removing particulate filter
⇒ page 474 .
♦ Four-wheel drive vehicles: catalytic converter ⇒ page 479 .
– Unscrew bolt -1-, and remove bracket -2-.
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t to the co
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c
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t.
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op
– Unscrew bolts -2- and bolt -3- and remove rear torque reaction C py
t. rig
support -1-.
gh ht
pyri by
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by
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Prote AG.

– Unscrew bolt -2- of oil supply line -3-.
Caution
• Oil supply line -3- must not be kinked when removing and
installing.
• Oil supply line -3- must be checked for damage after re‐
moving.
• Notes on checking ⇒ Item 19 (page 279) .
olksw
– Unscrew bolt s-4-
wagand
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oes up any escaping oil.
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– Pull hose -1- off vacuum unit -2-.
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Release connector -1- and pull off from vacuum unit with reg‐
in t
or
ulating flap potentiometer - G584- .

his
ate
do
priv
– Pull off hose -2- from vacuum unit with regulating flap poten‐
cum
for
tiometer - G584- -3-.

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t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Unscrew nuts -arrows- below and to the right of the turbo‐

charger.
– Unscrew nuts -arrows- below and to the left of the turbocharg‐
er.
AG. Volkswagen AG d
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– Unscrew union nut -4- of oil return line -3-. When doing this,
un
pt
an
counterhold on connection -5-. d
itte
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Caution
hole
spec
es, in part or in w
t to the co
• Avoid damage to oil supply line ⇒ Item 19 (page 279) .
Observe notes.
rrectness of i
linkage.
l purpos
• Do not hold onto the rod when removing the turbocharger.

nform
ercia
pipes and not by the rod.

m
a
com
t
Bent linkage will impair the function of the turbocharger.
ion in
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paintwork.
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– Remove turbocharger and carefully place aside. Cop py
ht. rig
rig ht
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cted agen
Prote AG.

– Once turbocharger has been placed aside, bolt -2- must be

released from bracket -1- for reinstalling.
Note information on oil return line ⇒ Item 15 (page 279) .
WARNING
The gasket has very sharp edges. Always wear gloves.
– Remove gasket from studs between turbocharger and cylinder

head.
Renew studs
Note
♦ Use a commercially available stud extractor to remove the two

studs from the 1st cylinder.
♦ Note the installation location of the studs.
. Volkswage n AG n AG d
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Volks not
Installing ed
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Install in reverse order
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th the following: eo
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– Renew seals, gaskets and self-locking nuts.
ce
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un
pt
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d

itte
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rm
– When turbocharger and connecting pipes are being assem‐ ab

pe
ility
ot
bled, it is essential that the correct repair set ⇒ ETKA (Elec‐ wit
, is n
tronic Parts Catalogue) is used.

h re
hole
spec
es, in part or in w
– Fit new double seal -2- onto the respective line connection
t to the co
-1- and secure by screwing in the corresponding banjo bolt

-3-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
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California 2010 ➤ , Caravelle 2010 ➤ , Multivan
aut 2010 ➤ , Transporter 20 ...
h
ra
s c
s rail) - Edition 08.2016
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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l purpos
nf
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o
rm
m
atio
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n in
c
Caution
or
thi
te
sd
iva
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rp
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f
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t.
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• Oil supply line -3- must be checked for damage after in‐ C py
ht. rig
stalling. rig ht
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co Vo
by lksw
• Notes on checking ⇒ Item 19 (page 279) . cted agen
Prote AG.

Torque settings
page 278
page 482
♦ Drive shafts; Assembly overview - drive shafts ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview - drive shaft
Stud 15 Nm

1.5 Removing and installing compressor

housing and turbine housing (bi-turbo)
Dismantling
– Remove securing clip -2-.
– Undo nuts -4-.
• Make sure that nut -6- does not turn as well.
AG. Volkswagen AG d
agen oes
– Unscrew bolt -1-. olksw not
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– Remove oil supply
thori line -2-. eo
au ra
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co

rrectness of i
– Remove oil return line -2-.

l purpos
nf
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orm
m
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or c
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Cop py
t. rig
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pyri by
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Prote AG.

AG. Volkswagen AG d
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– Remove nut -1-. olksw not
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nl
pt
du
an
itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Carefully pull apart compressor and turbocharger housing
rrectness of i
-arrows-; use ATE brake cylinder paste ⇒ Electronic parts
catalogue (ETKA) if necessary as a lubricant.
l purpos
Caution
nform
mercia
at
• When pulling apart, ensure that no pressure is exerted on
om
io
the linkage or the vacuum units.
n
c
in t
or
his
e

at
do
riv
pipes and not by the actuator or the rods.

p
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for
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• Bent linkage will impair the function of the turbocharger.

n
t.
yi Co
Loading/stressing the actuator can damage it. Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
Assembly
Assembly is carried out in reverse sequence; note the following:
– If necessary, renew studs (observe installation position). Use
commercially available stud extractor to do this.
– Insert control rod -1- in guide -5-.
– Insert studs in flange and assemble compressor and turbo‐
charger housing. If necessary, ATE brake cylinder paste ⇒
Electronic parts catalogue (ETKA) can be used as a lubricant.
– Tighten nuts -1-, while observing tightening sequence.

– Tighten nut -4-.

– Attach securing clip -2-.
– Apply sealing paint -3-.
– Install oil lines on turbocharger. To do this, first screw on oil
lines by hand and then tighten to specified torque.
– Once turbocharger is assembled, check vacuum unit with reg‐
ulating flap potentiometer - G584- ⇒ page 321 .
– If necessary, adjust vacuum unit with regulating flap potenti‐
ometer - G584- ⇒ page 327 .
Torque settings
Studs 15 Nm
1.6 Checking vacuum unit for turbocharger

⇒ “1.6.1 Checking vacuum unit for wastegate (bi-turbo)”,
page 321
⇒ “1.6.2 Checking vacuum unit with regulating flap potentiometer
G584 (bi-turbo)”, page 323
⇒ “1.6.3 Checking vacuum unit with position sender for charge
pressure positioner G581 (single turbo)”, page 325
1.6.1 Checking vacuum unit for wastegate (bi-

AG. Volkswagen AG d
agen
turbo)
oes
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Special tools and workshop equipment
tho
ris required e or
au ac
♦ Turbocharger tester - V.A.Gs1397A-
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Hand operated vacuum pump - VAS 6213-

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Test sequence n AG. Volkswagen AG do

lkswage es n
– Detach vacuum hose -1-. byV
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d ran
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Connect turbocharger tester - V.A.G 1397A- and hand vac‐
m
atio
m
uum pump - VAS 6213- to vacuum connection of vacuum unit

o
n in
c
-1- using a T-piece -2-.

or
thi
te
sd
a
– Switch on turbocharger tester - V.A.G 1397A- .

iv
o
r
rp
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o
m
– Set slide switch on turbocharger tester - V.A.G 1397A- to po‐
f
en
ng
t.
sition -II- (relative pressure).
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Using the hand vacuum pump - VAS 6213- , verify that the
vacuum unit has no leaks and that the travel mechanism is
free to move.
Note
♦ When the end position has almost been reached, pump slower
and carefully observe the linkage.
♦ The result will be falsified, if you keep on pumping after the
end position has been reached.
• The travel mechanism must start to move at a pressure of

-50 … -150 mbar (as indicated on the turbocharger tester -
V.A.G 1397A- ).
• The end position must be reached at a pressure of approx.
-350 to -450 mbar.
• The linkage -1- must be free to move without catching.
– Note the pressure values in mbar for the start and end of
movement. These values will be required during guided fault
finding ⇒ Vehicle diagnostic tester.
1.6.2 Checking vacuum unit with regulating

flap potentiometer - G584- (bi-turbo)
♦ Turbocharger tester - V.A.G 1397A-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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le
un
pt
an
d
itte
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erm
ab
ility
ot p

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Test sequence
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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– Connect turbocharger tester - V.A.G 1397A- and hand vac‐ s
ce
le
uum pump - VAS 6213- to vacuum connection of vacuum unit

un
pt
an
d
-1- using a T-piece -2-.

itte
y li
rm
– Switch on turbocharger tester - V.A.G 1397A- . ab

pe
ility
ot
wit
, is n
– Set slide switch on turbocharger tester - V.A.G 1397A- to po‐ h re

sition -II-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Using the hand vacuum pump - VAS 6213- , verify that the
free to move.
Note
and carefully observe the linkage.

-50 … -150 mbar (as indicated on the turbocharger tester -
V.A.G 1397/A- ).
• The end position must be reached at a pressure of approx.
-220 to -330 mbar (0.75 V).
• The linkage -1- must be free to move without catching.
1.6.3 Checking vacuum unit with position

sender for charge pressure positioner -
G581- (single turbo)
♦ Turbocharger tester - V.A.G 1397A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Test sequence
– Pull off vacuum hose.
– Connect turbocharger tester - V.A.G 1397A- -4- and hand
vacuum pump - VAS 6213- -3- with T-piece -2- to vacuum
connection of vacuum unit -1-.
– Switch on turbocharger tester - V.A.G 1397A- .
– Set slide switch on turbocharger tester - V.A.G 1397A- to po‐
sition -II-.
– Using the hand vacuum pump - VAS 6213- -3-, verify that the
free to move.
Note
and carefully observe the linkage -1-.

-50 … -150 mbar (as indicated on the turbocharger tester
agen
AG-. Volkswagen AG d
V.A.G 1397/A- ). Volksw
oes
not
g y ua
db ran
• The end position must be reached at a pressure
ris
e
of approx. tee
ho
-220 to -330 mbar (0.75 V). au
t or
ac
ss
• The linkage must be free to move in direction of -arrow- without
ce
e
nl
pt
du
catching.
an
itte
y li
erm
ab
ility

ot p
wit

, is n
h re
hole
– If necessary, adjust vacuum unit ⇒ page 327 .

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
aut California 2010 ➤ , Caravelle 2010 o➤ ra ,
Multivan 2010 ➤ , Transporter 20 ...
c
s
s 4-cylinder diesel engine (2.0 l engine, common rail) - Edition 08.2016
ce
e
nl
pt
du
an
itte
Adjusting vacuum unit with position sender for charge pressure
y li
erm
ab
positioner - G581- :
ility
ot p
– Loosen bolt -1-
wit
, is n
h re
hole
– Generate a vacuum of approx. 700 mbar in vacuum unit -5-.
spec
es, in part or in w
– Then shift bracket -6- in elongated holes to set a value of
t to the co
0.75 V.
Torque setting
rrectness of i
l purpos
Bolts for vacuum unit bracket 12 Nm
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
1.7 Renewing vacuum unit for turbocharger
t. C rig
gh ht
pyri by
Vo
o
by c
⇒ “1.7.1 Renewing and adjusting vacuum unit for wastegate (bi-
lksw
cted agen
Prote
turbo)”, page 327
AG.
⇒ “1.7.2 Renewing and adjusting vacuum unit with regulating flap

potentiometer G584 (bi-turbo)”, page 332
⇒ “1.7.3 Renewing vacuum unit with position sender for charge
pressure positioner G581 (single turbo)”, page 336
1.7.1 Renewing and adjusting vacuum unit for wastegate (bi-turbo)


equipment required
♦ Universal dial gauge holder
- VW 387-
♦ Hand operated vacuum
pump - VAS 6213-
♦ Turbocharger tester -
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
6341-
AG. Volkswagen AG d
agen oes
olks
w not
yV gu
1783- se
d b ara
nte
ri
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Removing
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Pull hose -2- off vacuum unit -1-.

– Remove securing clip -1-.

– Undo nuts -2-.
– Unscrew nuts -4- of vacuum unit -1-.
Note
In the illustration, only one nut can be seen from above.
– Remove vacuum unit from bracket of turbocharger -3-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Installing ise
d b ara
nte
or eo
h
Install in reverse order of removal, observing
s aut
the following: ra
c
s
– Carefully clean contact surfaces of vacuum unit.
ce
e
nl
pt
du
an
itte
– Install new vacuum unit -1- and secure to turbocharger bracket

y li
erm
ab
with nuts -4-.

ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ Location marker on vacuum unit must fit into mounting on tur‐

t to the co
bocharger.
♦ In the illustration, only one nut can be seen from above.
rrectness of i
♦ Use only new nuts from the replacement parts kit.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Guide control rod -1- through adjusting lever -2- on turbo‐

charger.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Tighten nuts -1-. s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Screw nut -3- by hand onto control rod -1- a few turns.
nform
mercia
Note
com
tion in
r
te o
For the following setting, first ensure that the lever arm -2- can be
thi
s
iva
moved in both end stops without being restricted by the nuts -3-
do
r
rp
and -4-.
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


uum pump - VAS 6213- with T-piece to vacuum connection
-2- of wastegate vacuum unit -1-.
– Switch on turbocharger tester - V.A.G 1397A- and move slid‐
ing switch on device to position II.
– Apply a vacuum of 390 ± 10 mbar to vacuum unit.
Caution
The following adjusting work must be carried out with extreme

care and precision as, otherwise, there is a risk that the turbo‐
charger will be damaged.
– Push lever arm -2- on turbocharger in direction of -arrow-

against its internal stop (wastegate closed).
– Screw nut -4- against lever arm -2- and counterhold with nut
-3-.
Note
Make sure that the control rod -1- does not turn at the same time.
– Reduce vacuum again and apply a vacuum of 390 ± 10 mbar

to vacuum unit again.
• Flap lever must now be resting against the stop (closed posi‐
tion). en AG. V
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ss precisely and in or‐
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– Repeat process approx. 3 to 5 times.
itte
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– Screw flat button - VAS 6341/4- onto dial gauge - VAS 6341- .
– Secure dial gauge - VAS 6341- with universal dial gauge
bracket - VW 387- on cylinder block -2-.
– Adjust dial gauge - VAS 6341- with flat button - VAS 6341/4-
until it reaches control rod -1- of turbocharger.
AG. Volkswagen AG d
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unit do not cant during the test.
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du
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t to the co
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– Attach hose -1- to vacuum unit -2-.

Torque settings
Vacuum unit nut 8 Nm
1.7.2 Renewing and adjusting vacuum unit with regulating flap potentiometer -
G584- (bi-turbo)


equipment required
♦ Hand operated vacuum
pump - VAS 6213-
♦ Turbocharger tester -
V.A.G 1397A-
1783-
AG. Volkswagen AG d
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Removing
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– Four-wheel drive vehicles: Removing catalytic converter
gh ht
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⇒ page 479 .
op Vo
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– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Remove engine support ⇒ page 34 .
– Connect hand vacuum pump - VAS 6213- to vacuum connec‐
tion of vacuum unit with regulating flap potentiometer - G584- .
– Unclip locking plate.
– Apply a vacuum of approx. 300 mbar to regulating flap poten‐
tiometer - G584- -3-.

– Undo nuts -2-.
– Remove nut -2-. AG. Volkswagen AG d

agen oes
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– Remove vacuum unit with regulating flap potentiometer - by V ol not
gu
G584- and heat shield -3-. rised ara
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Installing
rrectness of i
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Note
nform
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For the threaded connection of the vacuum unit with regulating

flap potentiometer - G584- always use new nuts.
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– Carefully clean contact surfaces of vacuum unit with regulating
thi
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flap potentiometer - G584- -1- and bracket -2-.
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– Bring heat shield -3- into position and tighten vacuum unit with C py
ht. rig
regulating flap potentiometer - G584- with new nuts -2-. rig ht
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California
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2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 r a ➤ , Transporter 20 ...
s c
s 4-cylinder diesel engine (2.0 l engine, common rail) - Edition 08.2016
ce
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– Screw nut -2- onto control rod a few turns.
itte
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Note
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For the following adjustment measures, first ensure that the lever
es, in part or in w
arm -3- can be moved in both end stops without being restricted
t to the co
by the nuts -2- and -4-.
rrectness of i
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– Re-connect electrical connector -1-.

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Do not attach hose -2-.
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– Select diagnosis function Turbocharger high-pressure co Vo
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bypass valve for turbine inlet, raw voltage .
agen
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uum pump - VAS 6213- with a T-piece to vacuum connection
of vacuum unit with regulating flap potentiometer - G584- .
– Switch on turbocharger tester - V.A.G 1397A- and move slid‐
ing switch on device to position II.
– Apply a vacuum of 500 ± 50 mbar to vacuum unit with regu‐
lating flap potentiometer - G584- .
– Move lever arm -1- in direction of -arrow- to closed position

until arm comes into contact.
– Screw nut -3- on control rod further until it comes into contact
with lever arm -1-.
– Continue turning nut -3- until a voltage of 0.75 volt (± 0.02 volt)
of vacuum unit with regulating flap potentiometer - G584- is
reached.
– Hand-tighten nut -2- to counterlock.
– Tighten nut using torque wrench - V.A.G 1783- and open jaw
attachment AF 10 - V.A.G 1783/1- .
Note
Make sure that the control rod does not turn by counterholding
the nut with the open-ended spanner.

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ss
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– Slowly reduce vacuum. Lever arm -1- now moves in direction
itte
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rm
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– Apply a vacuum of 500 ± 50 mbar again to vacuum unit with
wit
regulating flap potentiometer - G584- . , is n
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spec
– Check adjustment position again via voltage value 0.75 volt (±
es, in part or in w
0.02 volt) of vacuum unit with regulating flap potentiometer -
t to the co
G584- .
– If necessary, adjust again.
rrectness of i
– Slowly release vacuum; lever arm -1- must now be resting
l purpos
against the stop.

– If the flap lever is not resting against the stop, the setting pro‐
nform
ercia
cedure must be repeated until the setting values agree with

each other.
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– Then secure nuts with sealing paint from spare parts kit.
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– Press retaining clip from spare-parts kit onto control rod and
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turn 90° in the -direction of the arrow-.
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– Reconnect vacuum hose -2-.

Torque settings
♦ ⇒ “2.2 Assembly overview - catalytic converter, four-wheel
Control rod nuts 8 Nm
1.7.3 Renewing vacuum unit with position

G581- (single turbo)
Vacuum unit with regulating flap potentiometer - G581- cannot be
renewed individually. Removing and installing turbocharger
⇒ page 284 .
1.8 Removing and installing connecting pipes (bi-turbo)


equipment required
♦ Setting gauge - 3371-
1331- agen
AG. Volkswagen AG d
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♦ Set of plugsedfor
by engine -
V ua
ran
VAS 6122-
ho
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t or
au ac
♦ Ringssratchet spanner, 13
mm AF - T10384-
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Removing
Note


AG. Volkswagen AG d
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t to the co
– Open screw-type clip -2- far enough to enable removal of de‐
livery hose -1- from pulsation damper -3-.
rrectne
– Tie pressure hose -1- to one side.
ss o
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mer
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– Unscrew bolt -1- from bracket -3- (beneath the pipes) and re‐
move the connecting pipes -2-.

AG. Volkswagen AG d
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orise 2010 ➤ , Multivan 2010 ➤ , Transporter nte 20 ...
eo
h
4-cylinder diesel
s a engine (2.0 l engine, common rail) - Edition 08.2016
ut ra
c
s
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– Only loosen nut -2- in order to be able to turn the bracket -1-
pt
an
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so that the connecting pipes can be fitted.
itte
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– Open clip -2- and pull off heat protection hose -1-.
nform
mer
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– Remove connecting/sealing pipe -arrow-.

– Use brake cleaner to clean all sealing surfaces and contact
surface for insulated hose.
Installing
– When turbocharger and connecting pipes are being assem‐
bled, it is essential that the correct repair set ⇒ ETKA (Elec‐
tronic Parts Catalogue) is used.
– Apply a thin coat of lithium grease to sealing surfaces

-arrows- of turbocharger -1- and connecting pipes -3- ⇒ ETKA
(Electronic Parts Catalogue)
– Before fitting new O-ring -2-, apply a thin coat of lithium grease
to O-ring and insert O-ring into turbocharger ⇒ ETKA (Elec‐
tronic Parts Catalogue) .

– Insert the new connecting/sealing pipe -arrow- into the con‐

necting pipe and press it in by hand until it reaches the stop.
– Fit new screw-type clip and new insulated hose hand-tight on
turbocharger, but do not tighten.
– Insert the connecting pipes into the turbocharger without jam‐

ming them. You should be able to hear and feel how the
connecting/sealing pipe -arrow- latches into the turbocharger.
AG. Volkswagen AG d
agen oes
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y V gu
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– First, screw in the new bolts -arrows- hand-tight. s au ra
c
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nl
pt
du
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ab
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• Bolt -2- of bracket -1- must be loose.

nform
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c
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– Place connecting pipes -2- against bracket -3- and screw in

bolt -1- hand-tight.
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– Press connecting pipes against bracket by hand and screw in
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bolts -arrows- only hand-tight.
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– Only screw in bolt -1- hand-tight.

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– Use adjusting gauge - 3371- to measure distance -a- between

turbocharger and connecting pipes at three places. The dis‐
tance -a- must measure 5 to 6 mm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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– First tighten bolts -arrows-. aut ra
c
ss
ce
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nl
pt
du
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itte
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ab
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, is n
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es, in part or in w
t to the co
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– Then tighten bolt -1-.
nf
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orm
m
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– Tighten nut -2- with ratchet wrench 13 mm - T10384- .

– Stretch new insulated hose -1- so that contact surfaces of tur‐

bocharger and connectingwapipes
gen AGare completely
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– Fasten insulated hose d b -1- to the connecting pipes with the
y ua new
ran
se
screw-type clip hor-2-.
i Then pull insulated hose -1- down to tur‐
tee
ut
bocharger stops.
a
or
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Torque settings
un
pt
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d
itte
♦ ⇒ “1.2 Assembly overview – connecting pipes (bi-turbo)”, page
y li
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282
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page 278
hole
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Cop py
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2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 344
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 347
⇒ “2.3 Removing and installing charge air cooler”, page 350
⇒ “2.4 Removing and installing charge air pressure sender G31 /
intake air temperature sender G42 ”, page 354
⇒ “2.5 Removing and installing exhaust gas flap valve N220 ”,
page 355
⇒ “2.6 Removing and installing charge pressure control solenoid
valve N75 ”, page 356
AG. Volkswagen AG d
⇒ “2.7 Checking charge air system for leaks”, page 358 agen oes
olksw not
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⇒ “2.8 Removing and installing charge pressure sender 2 G447orise nte
”, page 361 auth eo
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2.1 Assembly overview - charge air system
ce
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d
itte
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⇒ “2.1.1 Assembly overview - charge air system bi-turbo engine
erm
ab
”, page 344
ility
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⇒ “2.1.2 Assembly overview - charge air system single turbo en‐
is n
h re
gine ”, page 346
ole,
spec
2.1.1 Assembly overview - charge air system
t to the co
“bi-turbo engine”
rrectne
Caution
ss
Screw-type clips on the charge air lines must always be tight‐
o
cial p
f
ened with specified torque. If the tightening torque is too low
inform
or too high, the charge air hose may slip off the charge air pipe
mer
when the vehicle is being driven.
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om
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1 - Intercooler
⇒ page 350
2 - Bolt
❑ 5 Nm
3 - Clip
❑ Observe notes
⇒ page 347
❑ 5.5 Nm
4 - Connection hose
tion ⇒ page 345 .
5 - Connection hose
tion ⇒ page 345 .
6 - Connection hose
tion ⇒ page 345 .
7 - Union
8 - O-ring
leaking
9 - Intake air temperature
sender - G42- with charge air
pressure sender - G31-
⇒ page 354
10 - Bolt
❑ 2 Nm AG. Volkswagen AG d
agen oes
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Installation position of connecting hoses s
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nl
pt
du
– Install connecting hose in such a way that marking -1- on con‐ an

itte
necting hose aligns with marking -2- on respective connecting y li

erm
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piece. ility
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345
AG.
2. Charge air system
2.1.2 Assembly overview - charge air system

“single turbo engine”
Caution
Screw-type clips on the charge air lines must always be tight‐

1 - Clip
❑ Observe notes
⇒ page 347
❑ 5.5 Nm
2 - Connection hose AG. Volkswagen AG d
agen oes
❑ Note installation posi‐ olksw not
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tion ⇒ page 347ised. b ara
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3 - Bolt aut or
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❑ 8 Nm ce
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pt
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4 - Sleeve
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5 - Rubber grommet
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6 - Connecting pipe
spec
es, in part or in w
❑ Observe notes
t to the co
⇒ page 347
7 - Bolt
rrectness of i
❑ 2 Nm
l purpos
8 - Intake air temperature

sender - G42- with charge air
pressure sender - G31-
nf
ercia
or

m
m
atio
⇒ page 354
om
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9 - Fastener
thi
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sd
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10 - Connection hose
o
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f

en
ng
t.
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tion ⇒ page 347 .
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❑ Observe notes rig ht
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⇒ page 347 co Vo
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11 - Union
13 - O-ring
❑ The O-ring must not be twisted.
❑ Renew if damaged or leaking.
14 - Retaining clip
15 - Bolt
❑ 5 Nm

16 - Intercooler
Installation position of connecting hoses

necting hose aligns with marking -1- on respective connecting
piece.
2.2 Assembly overview - charge-air hose

connections
⇒ “2.2.1 Notes on hose connections with screw-type clips”, page
347
⇒ “2.2.2 Separating and connecting line connections with plug-in
connector (VDA connector)”, page 348
⇒ “2.2.3 Installing hose connections with plug-in connectors”,
page 349
2.2.1 Notes on hose connections with screw-

type clips
AG. Volkswagen AG d
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Caution d by V gu
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Screw-type clips on the charge
s au
air lines must always be tight‐ ra
c
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pt
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Conventional screw-type clips are used on the hose connections

h re
on the “intake side”.

hole
spec
es, in part or in w
Screw-type clips with “barbs” -arrows- are used on the hose con‐
t to the co
nections on the “discharge side”.
Caution
rrectness of i
l purpos
• Do not loosen these hose clips and pull them back over
the hose. Risk of damage to hose!
nf
ercia
• If a clamp has been removed, it must be renewed together

orm
with the hose.

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om
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Prote AG.
2. Charge air system 347

Screw-type clips with locking hooks -arrows- must only be loos‐

ened.
– Loosen bolt of screw-type clips -1- sufficiently to allow for re‐
moving hoses.
Screw-type clamps that have only been loosened can be re-used.
Hose and clamp are supplied together as one spare part.
– When installing, does not use any fluid containing oil, silicone
or grease. Only use clean water.
2.2.2 Separating and connecting line connec‐

tions with plug-in connector (VDA con‐
nector)
Caution
Seal for plug-in connector may be damaged if pipe is pressed

slanted into coupling piece.
This would result in a leak, which may lead to a breakdown.
Do not use any fluid containing oil, silicone or grease. Only use
clean water.
Observe procedure.
Disconnecting
– Press hose -1- and pipe -3- together -arrows- so that retaining
clip -2- can be raised and engaged in mounting bracket -4-.
n AG. Volkswagen A age G do
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– Pull retaining clip -1- on both sides vertically upwards

-arrows A- into mounting bracket -2-.
– Only pull line apart longitudinally when retaining clip -1- has
engaged in mounting bracket -2- -arrows B-.
– Clean sealing surfaces and seal. They must be free of oil and
grease. gen AG
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– If necessary, wet the cleaned sealing ring -arrow- with clean
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water for assembly.
l purpos
Caution
nform
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• Insert pipe longitudinally into coupling piece and press to‐

m
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ate
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– Press pipe longitudinally into coupling piece to stop. Retaining py by
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clip -1- engages in groove -2- in this case.
by lksw
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Prote AG.
• The following test must be carried out each time after assem‐
bling.
– Pipe must then be pulled back again to check whether retain‐
ing clip -1- has engaged in groove -2-.
2.2.3 Installing hose connections with plug-in

connectors
Caution
The sealing ring for the push-on coupling can be damaged if

the retaining clip is in the locked position during installation.
This would result in leaking.
Do not use any fluid containing oil, silicone or grease. Only use
clean water.

AG. Volkswagen AG d
agen oes
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V gu
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4-cylinder diesel enginethori(2.0
s
l engine, common rail) - Edition 08.2016 e or
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ss
Removing
ce
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pt
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– Release plug-in connector by pulling out retaining clip
itte
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erm
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Installing
hole
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es, in part or in w
– When replacing the sealing ring, place the sealing ring in the
t to the co
groove of the charge air hose.
– Make sure that the sealing ring is completely resting in the
groove all around the hose. Make sure that the sealing ring is
rrectness of i
not twisted.
l purpos
– Apply clean water to sealing surfaces and sealing ring.
nform
ercia
– Bring retaining clip to release position -1-.

m
at
om
– Push charge air hose into coupling as far as stop.
ion
c
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or
– Bring retaining clip to locking position -2- and then press
his
ate
charge air hose again.
do
priv
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or
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f
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ed and engaged.
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Cop py
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pyri by
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2.3 Removing and installing charge air cool‐

er
⇒ “2.3.1 Removing and installing charge air cooler bi-turbo engine
”, page 350
⇒ “2.3.2 Removing and installing charge air cooler single turbo
engine ”, page 352
2.3.1 Removing and installing charge air cool‐

er “bi-turbo engine”

♦ Socket set 1/4", 22-piece - VAS 5528-
Removing
Note agen
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nl
pt
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– Remove front bumper cover ⇒ General body repairs, exterior;
ility
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Rep. gr. 63 ; Front bumper; Removing and installing bumper
wit
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cover .
h re
hole
spec
– Loosen pressure hose clamp on pulsation damper and pull off
es, in part or in w
pressure hose.
t to the co
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– Unscrew bolt -1- from bracket -2- on left and right and remove
erm
ab
bracket -2-.
ility
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– Unscrew bolt -3- from charge air cooler -4- on right and left.
h re
ole,
Remove charge air cooler -4- out of mounting -5- on left and
spec
right.
t to the co
Installing
rrectne
Torque settings
s
♦ ⇒ “2.1.2 Assembly overview - charge air system single turbo

s o

cial p
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mer
atio

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Prote AG.

AG. Volkswagen AG d
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♦ Socket set 1/4",by
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Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
ss
Rep. gr. 63 ; Front bumper; Removing and installing bumper

o
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cover .
inform
mer
Lift retaining clips -1- on left and right and pull pressure hose -2-
atio
off charge air cooler on left and right.

om
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Prote AG.

– Unscrew bolt -1- from bracket -2- on left and right and remove
bracket -2-.
– Unscrew bolt -3- from charge air cooler -4- on right and left.
Remove charge air cooler -4- out of mounting -2- on left and
right.
Installing
Torque settings
♦ ⇒ “2.1.2 Assembly overview - charge air system single turbo
2.4 Removing and installing charge air pres‐ lkswage

es n
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sure sender - G31- / intake air tempera‐
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Removing
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wage common rail) - d
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– Release connector -1- and pull off. ris
ed
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un
pt
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Installing
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Torque settings
ole,
spec
♦ ⇒ “2.1 Assembly overview - charge air system”, page 344
t to the co
rrectne
tank
ss
2.5 Removing and installing exhaust gas
o
cial p
f in
flap valve - N220-
form
mer
atio
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Cop py
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pyri by
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Prote AG.
Removing
Note
For greater clarity, illustration shows exhaust flap valve - N220-

from below.
– Pull off connectors and vacuum lines.

– Unscrew nuts -1- and remove exhaust flap valve - N220- -2-.
Installing
Caution
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.
Push all hoses onto stop or at least 10 mm onto the respective
connection.
Torque settings
⇒ “1.1.2 Assembly overview - turbocharger, bi-turbo”, page 278
2.6 Removing and installing charge pres‐

sure control solenoid valve - N75-
⇒ “2.6.1 Removing and installing charge pressure control sole‐
noid valve N75 , bi-turbo engine ”, page 356 n AG. Volkswagen AG age does
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⇒ “2.6.2 Removing and installing charge pressureyV
ol control sole‐ gu
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noid valve N75 , single turbo engine ”, page
rise 357 nte
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2.6.1 Removing and installing
ss
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charge pres‐ c
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sure control solenoid valve - N75- , “bi-

un
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Cop py
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Prote AG.

Removing
Note
For purposes of clarity, illustration shows charge pressure control

solenoid valve - N75- from above.

– Unscrew nuts -1- and remove charge pressure control sole‐
noid valve - N75- -2-.
Installing
Caution
connection.
Torque settings
page 278
2.6.2 Removing and installing charge pres‐

sure control solenoid valve - N75- , “sin‐
gle turbo engine”
♦ Torque wrench - V.A.G 1410- agen
AG. Volkswagen AG d
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2. Charge air system
Removing
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For purposes of clarity, illustration shows charge pressure control
ed
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solenoid valve - N75- from aut above.
h eo
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pt
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– Unscrew nuts -1- and remove charge pressure control sole‐
erm
ab
noid valve - N75- -2-.
ility
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Installing
h re
hole
spec
es, in part or in w
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Caution
rrectness of i
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connection.
nform
mercia
at
om
io
Torque settings
n
c
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or
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e
♦ ⇒ “1.1.1 Assembly overview - turbocharger, single turbo”,

at
do
riv
page 273
p
cum
for
en
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t.
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2.7 Checking charge air system for leaks
Co
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♦ Charge air system tester - V.A.G 1687-
Prote AG.
♦ adapters - V.A.G 1687/10-

♦ Engine plug set - VAS 6122-

4-cylinder diesel gengine
en AG. V (2.0 al gengine,
olksw en AG common rail) - Edition 08.2016
dwa oes
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Removing ed
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– Remove connecting pipe -arrow-.
au
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– Seal union with a bung -2- (diameter 28 mm) from engine bung
ce
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nl
pt
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set - VAS 6122- and secure with a clip -1-.
an
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– Remove intake hose -1- from air filter.

p
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– Insert adapter - V.A.G 1687/10- into intake hose -1- and se‐
en
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t.
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cure with a clip. t. Cop py
rig
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Prepare charge air system tester - V.A.G 1687- as follows: yri
p by
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Prote AG.
– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

– Connect charge air system tester - V.A.G 1687- to adapter -

V.A.G 1687/10- as shown.
AG. Volkswagen AG d
agen oes
olksw not
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priv
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- , using a standard con‐
necting piece.
Note
Drain water in sight glass by removing drain plug -6-.
– Open valve -3-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high, this can cause damage to the charge air system.
– Adjust pressure to 0.5 bar with pressure control valve

en A-2-.
G. Volkswagen AG
ag does
lksw not
– Open valve -4- and wait until test circuit is
db
full.
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– Check charge air system for leaksss aas follows: c
ce
le
♦ by listening
un
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d
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♦ by feeling
rm
ab
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♦ with leak detector spray
ot
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♦ or with the ultrasonic tester - V.A.G 1842- .
hole
spec
es, in part or in w
t to the co
Note
♦ Slight leaks on the intake side of turbocharger are permissible,
rrectness of i
as the intake hoses are not designed for high-pressure.
l purpos
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
nform
ercia
♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions .

m
a
com
♦ If a leak has been located, observe notes on charge air system

ion in
specified in assembly work ⇒ page 347 .

r
te o
thi
s
iva
♦ Depressurise test circuit by detaching coupling from adapter -

do
r
rp
V.A.G 1687/10- before removing adapter.

um
fo
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ng
t.
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Cop py
t. rig
2.8 Removing and installing charge pres‐
gh ht
pyri by
Vo
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sure sender 2 - G447-
c by lksw
cted agen
Prote AG.


Removing
Note

– Unscrew banjo bolt from turbocharger.
– Unscrew bolts -1- and remove charge pressure sender 2 -
G447- .
Installing
wage e
Install in reverse order of yremoval,
Vol
ks observing the following:
s no
tg
b ua
ed ran
Torque settings horis tee
t or
au ac
♦ ⇒ “2.1 Assembly
ss overview - charge air system”, page 344
ce
le
un
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an
d
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erm
ab
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t to the co
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cial p
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mer
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c
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Cop py
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by c lksw
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Prote AG.

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 363
⇒ “1.2 Schematic overview - fuel system”, page 371
⇒ “1.3 Assembly overview - fuel system”, page 373
⇒ “1.4 Checking fuel system for leaks”, page 378
1.1 Overview of fitting locations - injection system
1 - Air mass meter - G70-

2 - Intake manifold pressure
sender - G71-
3 - Hall sender - G40-
❑ Location ⇒ page 367 .
⇒ page 508
4 - Vacuum unit for exhaust
flap
❑ Vehicles with “bi-turbo
engine” only.
5 - Position sender for charge
pressure positioner - G581- or
vacuum unit with regulating
flap potentiometer - G584-
❑ Vacuum unit with regu‐ n AG. Volkswagen AG do
lating flap potentiometer lkswage es n
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- G584- in vehicles with d byV ua
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❑ Position sender for ss
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charge pressure posi‐
ce
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nl
tioner - G581- in vehi‐

pt
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6 - Fuel pressure sender -

hole
spec
G247-
es, in part or in w
t to the co

7 - Exhaust gas flap valve -
N220-
rrectness of i
❑ Vehicles with “bi-turbo

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
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for
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t.
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Cop py
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pyri by
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by
363
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Prote AG.
1. Injection system
engine” only.
8 - Charge pressure control solenoid valve - N75-
❑ Fitting location in vehicles with “bi-turbo engine” ⇒ page 367 .
❑ Fitting location in vehicles with “single turbo engine” ⇒ page 367 .
wage oes
9 - Exhaust gas recirculation cooler changeover valve Vol- N345-
ks not
gu
d by ara
❑ Fitting location in vehicles with “bi-turbooengine”
ris
e ⇒ page 367 . nte
th eo
❑ Fitting location in vehicles with “single
s au turbo engine” ⇒ page 367 . ra
c
s
ce
e
10 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
nl
pt
du
an
❑ In vehicles with “single turbo engine” only.
itte
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erm
ab
ility
ot p
wit
11 - Supplementary fuel pump - V393-
, is n
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hole
spec
es, in part or in w
12 - Intake air temperature sender - G42- with charge air pressure sender - G31-
t to the co
13 - Engine (motor) control unit - J623-
rrectness of i
l purpos

nf
ercia
or
❑ In vehicles with “single turbo engine” only.
m
m
atio
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or c
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15 - Radiator outlet coolant - G62-
o
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t.
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op
❑ Removing and installing ⇒ page 232 C py
t. rig
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yri
16 - Exhaust gas pressure sensor 1 - G450-
p by
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by c lksw
cted
❑ Adaptation must be carried out after renewing.
agen
Prote AG.

17 - Engine speed sender - G28-
18 - Fuel pressure regulating valve - N276-
❑ Vehicles with “bi-turbo engine” only.
20 - Injectors (piezo injectors)
❑ Injector, cylinder 1 - N30-
21 - Throttle valve module - J338- with throttle valve potentiometer - G69- and intake manifold flap motor -
V157-
364 Rep. gr.23 - Mixture preparation - injection

24 - Fuel metering valve - N290-
25 - Fuel temperature sender - G81-
26 - Pressure retention valve
27 - Glow plugs
❑ Glow plug 1 - Q10-
❑ Glow plug 4 l-ksQ13-
wage es n
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❑ Location y Vpage 89 .
b⇒ ua
ed ran
is tee
or
28 - Charge
au
th pressure sender 2 - G447- or
ac
ss
ce
e
nl
pt
du
❑ Adapt after renewal ⇒ Vehicle diagnostic tester.

an
itte
y li
❑ Removing and installing ⇒ “1.1.2 Assembly overview - turbocharger, bi-turbo”, page 278
erm
ab
ility
ot p

wit
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A - Brake light switch on brake master cylinder - F-

hole
spec

es, in part or in w
t to the co
B - Clutch pedal switch - F36-

❑ Only fitted to vehicles with a manual gearbox
rrectness of i

l purpos
C - Clutch position sender - G476-

nf
ercia
D - Acceleration pedal position sender - G79-

orm
m
atio

om
n in
c
E - Exhaust temperature sender 1 - G235- or exhaust temperature sender 2 - G448-

or
thi
te
sd
a
❑ Installed in exhaust manifold/turbocharger.

iv
o
r
rp
cu
❑ Exhaust temperature sender 1 - G235- , only on 84, 100 and 103 kW engines. Fitting location, item 8
o
m
f
en
ng
⇒ Item 6 (page 274) .

t.
yi Co
op py
❑ Exhaust temperature sender 1 - G235- , only on 132 kW engines. Fitting location, item 28
t. C rig
gh ht
⇒ Item 28 (page 280) . yri
p by
co Vo
by lksw
❑ Exhaust temperature sender 2 - G448- , only on 62 and 75 kW engines. Fitting location, item 7
cted agen
Prote AG.
F - Exhaust gas temperature sender 3 - G495-
G - Exhaust gas temperature sender 4 - G648-
H - Lambda probe - G39-
I - Fuel pump relay - J17-
1. Injection system 365

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ut ➤ , Transporter 20 ...
ho eo
ra
a
s - Edition 08.2016
s c
ce
e
nl
pt
du
an
J - Relay for supplementary fuel pump - J832-
itte
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erm
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ility
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K - particulate filter
wit
, is n
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hole
spec
es, in part or in w
t to the co
Engine control unit - J623-
Electronics box fitting location in front left of engine compartment.
rrectness of i
1- Engine (motor) control unit - J623-
l purpos
2- 94-pin connector - T94-
nf
ercia
3- 60-pin connector - T60-
orm
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atio
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t.
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Fitting locations on top and front of engine

1- Fuel pressure sender - G247-
2- Pressure retention valve
3- Throttle valve module - J338- with throttle valve potentiom‐
eter - G69- and intake manifold flap motor - V157-
4- Fuel pressure regulating valve - N276-
5- Fuel temperature sender - G81-
6- Fuel metering valve - N290-
Components on top of engine

1- Fuel pressure sender - G247-
2- Injector, cylinder 1 - N30-
6- Exhaust gas recirculation valve - N18- with exhaust gas re‐
circulation potentiometer - G212-
7- Exhaust gas pressure sensor 1 - G450-

Charge pressure sender 2 - G447- -arrow-

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Solenoid valves, bi-turbo engine
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1- Charge pressure control solenoid valve - N75-
2- Exhaust gas recirculation cooler changeover valve - N345-
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3- Exhaust gas flap valve - N220-
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Hall sender - G40-

Vacuum unit for exhaust flap

♦ In vehicles with “bi-turbo engine” only.
1- Vacuum hose
2- Vacuum unit for exhaust flap
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Position sender for charge pressure positioner - G581- or vacuum

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unit with regulating flap potentiometer - G584-
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3- Vacuum unit for wastegate
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Coolant temperature sender - G62- -2-

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Radiator outlet coolant temperature sender - G83-

♦ In vehicles with “single turbo engine” only.
1- Retaining clip
2- Radiator outlet coolant temperature sender - G83-
3- Electrical line connection at coolant temperature sender -
G62-

Engine speed sender - G28-

Fitting location beneath oil filter bracket.
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Brake light switch on brake master cylinder - F-
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Brake light switch - F- with brake pedal switch - F47- -arrow- is
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Clutch pedal switch - F36-

1- Electrical line connection
2- Mounting bracket

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Intake air temperature sender - G42- with charge air pressure

sender - G31-
Fitting location beneath expansion tank.
Radiator outlet coolant temperature sender - G83-

♦ In vehicles with “bi-turbo engine” only.
Fitting location on lower left in front of engine.

1.2 Schematic overview - fuel system
WARNING
♦ Read through the rules for cleanliness and the instructions

for working on the fuel system ⇒ page 10 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
♦ If components of the fuel system between the fuel tank . Volkswagen AG
and the high-pressure pump are removed or renewed, the kswagen AG does
fuel system must be filled to be bled ⇒ Vehicle diagnostic byV
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1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
2 - fuel filter.
❑ With pre-heating valve.
❑ Assembly overview -
fuel filter ⇒ page 259 .
⇒ page 259
3 - Supplementary fuel pump -
V393-
⇒ page 259
4 - Filter strainer
5 - Fuel temperature sender -
G81-
❑ After renewing, initial
fuel filling must be car‐
ried out (never allow the
pump to run while it is
still empty) ⇒ Vehicle di‐
agnostic tester.
⇒ page 454
7 - Fuel metering valve - N290-
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9 - High-pressure accumulator (fuel rail)

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10 - Fuel pressure sender - G247-

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Caution
Pressure
♦ retention valve
must not be disconnec‐
ted or pulled off whilst en‐
gine is running as this
destroys the injectors.
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❑ The pressure retention valve has the task of always maintaining a residual pressure (control volume) of
approx. 10 bar in the fuel return lines. The injectors require this control volume to function.
❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
rrectness of i
❑ Fill/bleed fuel system after exchanging ⇒ Vehicle diagnostic tester.
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❑ Check pressure retention valve ⇒ page 425 .

nform
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❑ Installing and removing ⇒ page 412

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1.3 Assembly overview - fuel system
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WARNING

♦ If components of the fuel system between the tank and the
high-pressure pump are removed or renewed, the fuel
system must be filled to be bled ⇒ Vehicle diagnostic test‐
er. (It is important not to allow the high-pressure pump to
run while still empty.)



1 - Fuel lines
❑ Cannot be renewed in‐
dividually.
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2 - Bolt Volksw
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3 - Hose ss a ra
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5 - Hose
❑ To fuel filter
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6 - Hose
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❑ From supplementary
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7 - Bolt
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❑ 10 Nm
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8 - Clip
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❑ For fuel line

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⇒ Item 23 (page 376) .

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9 - High-pressure line
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⇒ page 406
❑ 30 Nm
Note
♦ The high-pressure line may be

re-used after the following
checks:
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
♦ The inside of the line must not be
deformed, constricted or dam‐
aged.
♦ Corroded lines should no longer
be used.
10 - High-pressure accumulator (fuel rail)

11 - Sealing ring

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13 - O-ring
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– Clean sealing surface of injector in cylinder head and injector shaft.
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WARNING
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Only cleaning set - VAS

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6811- may be used for
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cleaning set - VAS

6811- .
❑ Do not interchange!
❑ When removing and installing, always renew the following components and seals/O-rings: “copper seal”
⇒ Item 15 (page 375) , “O-ring for injector bore” ⇒ Item 11 (page 94) , “O-ring for injector return con‐
nection” ⇒ Item 13 (page 375) and “bolt for clamping plate” ⇒ Item 18 (page 375) .
❑ Before re-using high-pressure lines ⇒ Item 9 (page 374) , perform visual check of taper seals for damage,
e.g. transverse scores or corrosion. Always renew if damaged.
❑ If removed injectors (piezo injectors), high-pressure lines ⇒ Item 9 (page 374) and clamping plates
⇒ Item 17 (page 375) are to be reinstalled, they must always be re-fitted in their original positions on the
same cylinder.
15 - Copper washer
16 - O-ring
17 - Clamping plates
❑ Reusable
18 - Bolt
❑ 8 Nm +270°
19 - Fuel return lines
❑ Cannot be renewed individually.
❑ To fuel tank
❑ The fuel return line must not be kinked, damaged or blocked.
❑ The fuel return lines must not be dismantled.
❑ Release ⇒ page 377 .
❑ Check locks ⇒ page 377
❑ Attach ⇒ page 378
❑ Lock ⇒ page 378

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Caution
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ted or pulled off whilst en‐
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t to the co
destroys the injectors.
Fuel
♦ return lines must not
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rrectness of i
pulled off whilst engine is
running as this destroys
l purpos
the injectors.
Residual
♦ pressure must
nform
ercia
not be lower or higher

m
at
than 10 bar as otherwise
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❑ Renewed together with fuel return lines.
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❑ The pressure retention valve has the task of always maintaining a residual pressure (control volume) of
yi Co
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approx. 10 bar in the fuel return lines. The injectors require this control volume to function.
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❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
py by
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cted
❑ Fill/bleed fuel system after exchanging ⇒ Vehicle diagnostic tester.
agen
Prote AG.
❑ Check pressure retention valve ⇒ page 425 .

21 - Fuel pressure sender - G247-
❑ 100 Nm
22 - Bolt
❑ 22 Nm
23 - Fuel line
Note
♦ The high-pressure line may be

re-used after the following
checks:
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
♦ The inside of the line must not be
deformed, constricted or dam‐
aged.
♦ Corroded lines should no longer
be used.
❑ 30 Nm
❑ With fuel metering valve - N290- (must not be opened).
❑ After renewing, initial fuel filling must be carried out (never allow the pump to run while it is still empty)
⇒ Vehicle diagnostic tester.
25 - Bolt

❑ 20 Nm +180°
26 - Bolt
❑ 20 Nm +45°
27 - Hub
28 - Bolt
❑ 20 Nm +90°
29 - Toothed belt pulley on high-pressure pump
30 - Nut
❑ 95 Nm
31 - Fuel temperature sender - G81-
32 - Hose
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Release fuelhreturn line nte
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– With engine
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replaced.


connections.
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1.4 Checking fuel system for leaks
DANGER!
♦ Observe safety precautions when working on diesel direct

injection fuel system ⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 10 .
These instructions must always be complied with before and
during work!
Test sequence
– Allow engine to idle for a few minutes without accelerating and
then switch off engine again. Fuel system will bleed itself au‐
tomatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.

– Then test drive the vehicle, accelerating to full throttle at least

once.
– Then check high-pressure section of fuel system again for
leakage.
Note
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch engine off and
clear event memory. Then continue road test.
AG. Volkswagen AG d
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2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 380
⇒ “2.2 Checking vacuum system for leaks, bi-turbo engine ”, page
384
⇒ “2.3 Checking vacuum system for leaks, single turbo engine ”,
page 391
⇒ “2.4 Checking vacuum system for leaks, four-wheel drive ”,
page 397
2.1 Connection diagram - vacuum system
Vol
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⇒ “2.1.1 Connection diagram - vacuum system, bi-turbo
ris engine ”,
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page 380 utho or
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⇒ “2.1.2 Connection diagram - vacuum system single turbo en‐
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2.1.1 Connection diagram - vacuum system, “bi-turbo engine”
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1 - Vacuum switch for rear dif‐

ferential lock - F363-
❑ Installed in vehicles with
four-wheel drive only.
❑ Further information
about function ⇒ Self-
study programme No.
333 ;
⇒ Rep. gr. 47 ; Brake
servo/brake master cyl‐
inder; Assembly over‐
view - brake servo/
brake master cylinder
❑ Checking ⇒ page 397 agen
AG. Volkswagen AG d
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2 - Non-return valve d by V gu
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❑ For differential lock uthor eo
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4 - Exhaust gas flap valve -
atio
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5 - Charge pressure control solenoid valve - N75-
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❑ 6 Nm
6 - Differential lock valve 2 - N126-
❑ Installed in vehicles with four-wheel drive only.
❑ Switches differential lock on.
❑ Switches differential lock off.
❑ For exhaust flap valve - N220- , charge pressure control solenoid valve - N75- and vacuum reservoir in
cylinder head cover
2. Vacuum system 381

9 - Exhaust gas recirculation cooler changeover valve - N345-
10 - T-piece
❑ Installed in brake servo
❑ Removing and installing ⇒ Rep. gr. 47 ; Brake servo/brake master cylinder; Assembly overview - brake
servo/brake master cylinder . Volkswage n AG n AG d
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11 - Non-return valve Vol
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❑ Installed in vehicles with four-wheel drive only. orise nte
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❑ For vacuum system to rear final drive. au ra
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12 - Vacuum unit
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❑ Vacuum reservoir is installed in cylinder head cover. Both parts can only be renewed together.
rrectness of i
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14 - Vacuum unit
❑ On turbocharger.
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2.1.2 Connection diagram - vacuum system “single turbo engine”

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Do not kink, twist orthcrush
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uum lines. This may au cause breakdowns. ra
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1 - Vacuum switch for rear dif‐
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spec
ferential lock - F363-
t to the co
❑ Further information
rrectne
about function ⇒ Self-
study programme No.
333 ;
ss o
cial p
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⇒ Rep. gr. 39 ; Final
form
mer
drive; Assembly over‐
atio
view - final drive
om
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sition
valve 1 - N125- .
sition
4 - Charge pressure control
solenoid valve - N75-
❑ 6 Nm
❑ Switches differential lock on.
❑ Switches differential lock off.

❑ For charge pressure control solenoid valve - N75- and vacuum reservoir in cylinder head cover.
8 - T-piece
❑ Installed in brake servo
❑ Removing and installing ⇒ Rep. gr. 47 ; Brake servo/brake master cylinder; Assembly overview - brake
servo/brake master cylinder
9 - Exhaust gas recirculation cooler changeover valve - N345-
❑ For vacuum system to rear final drive.
❑ Observe installation position AG. Volkswagen AG d
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❑ Checking ⇒ page 391 byV
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❑ Removing and installingh⇒ o page 492
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11 - Vacuum unit ss c
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❑ For changeover for exhaust gas recirculation cooler.

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12 - Position sender for charge pressure positioner - G581-
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❑ Vacuum reservoir is installed in cylinder head cover. Both parts can only be renewed together.
f inform

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n
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2.2 Checking vacuum system for leaks, “bi-

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⇒ “2.2.1 Checking vacuum hoses to non-return valve, solenoid
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valves N220 and N75 , changeover valve N345 and vacuum res‐ ht. rig
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ervoir”, page 386 py by
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⇒ “2.2.2 Checking vacuum hose to vacuum unit with regulating Prote AG.
flap potentiometer G584 ”, page 388
⇒ “2.2.3 Checking vacuum hose to vacuum unit on turbocharger”,
page 389
⇒ “2.2.4 Checking vacuum hose to vacuum unit on exhaust gas
recirculation cooler”, page 390

♦ Set of plugs for engine

gen AG
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Caution
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connection.
Checking vacuum hoses to non-return valve, exhaust gas flap

valve - N220- , charge pressure control solenoid valve - N75- ,
changeover valve for exhaust gas recirculation cooler - N345- and
vacuum reservoir ⇒ page 386 .
Check vacuum hose to vacuum unit with regulating flap potenti‐
ometer - G584- ⇒ page 388 .
Check vacuum hose to vacuum unit on turbocharger
⇒ page 389 .
Check vacuum hose to vacuum unit on exhaust gas recirculation
cooler ⇒ page 390 .
Check “four-wheel drive” vacuum system for leaks ⇒ page 397 .

2.2.1 Checking vacuum hoses to non-return

valve, solenoid valves -N220- and -
N75- , changeover valve -N345- and
vacuum reservoir
Test sequence
– Pull vacuum hose -1- off at outer connection of charge pres‐
sure control solenoid valve - N75- .
– Pull vacuum hose -2- off at outer connection of exhaust gas
recirculation cooler changeover valve - N345- .
Note
Illustration shows exhaust flap valve - N220- from below.
– Detach vacuum hose -arrow- at outer connection of exhaust

flap valve - N220- .
– Connect hand vacuum pump - VAS 6213- to the 3 valves one
after the other and then generate a vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
AG. Volkswagen AG d
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– Replace a leaking valve. olksw not
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– Seal vacuum hoses -1- to -3- with clean bungs from engine ss c
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at
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ion
c
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or
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ate
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en
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t.
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– Pull vacuum hose -1- off connecting piece -2-.

– Seal connecting piece -2- with a clean bung from engine bung
set - VAS 6122- .
– Pull vacuum hose -1- off T-piece -2-.

– Connect hand vacuum pump - VAS 6213- to removed end of
vacuum hose and generate a partial vacuum of 0.6 bar.
AG. Volkswagen AG d
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• Vacuum must not drop. Volksw
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If vacuum drops: orise nte
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– Locate damage or leaking vacuum hose connection.
ss a
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ce
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nl
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tion and check for leak to connected component.
du
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– Pull off vacuum hoses -1- and -2- at connector -arrow- and
ility
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check non-return valve and vacuum hose to exhaust gas re‐
wit
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circulation cooler changeover valve - N345- .
hole
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es, in part or in w
t to the co
– Renew non-return valve or leaking vacuum hose.
– Reconnect all vacuum hoses to valves and to union -arrow-.
rrectness of i
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nf
ercia
orm
m
atio
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– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening

o
n in
c
of vacuum hose with clean bung from engine bung set - VAS
or
thi
e
6122- .
t
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Cop py
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Prote AG.

– Connect hand vacuum pump - VAS 6213- to pulled-off end of

vacuum hose -1- and generate a partial vacuum of 0.6 bar.
If vacuum drops:
– If vacuum hose -1- leaks, renew it.
If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- to vacuum reservoir
and generate a partial vacuum of 0.6 bar.
If vacuum drops:
– Replace cylinder head cover if it leaks ⇒ page 107 .
If pressure does not drop: n AG. Volkswagen AG do
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– Check following vacuum hoses: d byV ua
ran
ir se tee
♦ Vacuum hose to vacuum unit with regulating flap potentiome‐
autho
or
ac
ter - G584- ⇒ page 388 ss
ce
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nl
♦ Vacuum hose to vacuum unit on turbocharger ⇒ page 389
pt
du
an
itte
y li
♦ Vacuum hose to vacuum unit on exhaust gas recirculation
erm
ab
cooler ⇒ page 390
ility
ot p
wit
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♦ Checking vacuum system for leaks, “four-wheel drive”
h re
hole
⇒ page 397
spec
es, in part or in w
t to the co
2.2.2 Checking vacuum hose to vacuum unit
with regulating flap potentiometer -
rrectness of i
G584-
l purpos
Test sequence
• Vacuum hoses to non-return valve, exhaust flap valve -
nform
ercia
N220- , charge pressure control solenoid valve - N75- , ex‐

m
haust gas recirculation cooler changeover valve - N345- and

at
om
vacuum reservoir must first have been checked for leaks ion
c
in t
r
⇒ page 386 .
o
his
ate
do
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Note
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Illustration shows exhaust flap valve - N220- from below.
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flap valve - N220- .
– Observe pressure gauge of hand avacuum
gen AG pump - nVAS
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noise insulation .
pe
ility
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– Pull off vacuum hose -arrow- from vacuum unit with regulating
h re
hole
flap potentiometer - G584- . Seal opening of vacuum hose with
spec
clean bung from engine bung set - VAS 6122- .
es, in part or in w
t to the co
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a partial vacuum of 0.6 bar.
rrectness of i
l purpos
nform
ercia
If vacuum drops:
m
a
– Renew leaking vacuum hose.
com
tion in
r
te o
thi
s
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do
– Connect hand vacuum pump - VAS 6213- to vacuum unit with
r
rp
c
potentiometer for regulating flap - G584- and generate a vac‐
um
fo
en
g
uum of 0.6 bar.

n
t.
yi Co
Cop py
– Observe pressure gauge of hand vacuum pump - VAS 6213- ht. rig
rig ht
for approx. 30 seconds. py by
co Vo
by lksw
cted agen
• Vacuum must not drop. Prote AG.
If vacuum drops:
– Replace turbocharger ⇒ page 298 .

on turbocharger
Test sequence
vacuum reservoir must first have been checked for leaks
⇒ page 386 .
– Pull vacuum hose -1- off at central connection of charge pres‐


If vacuum drops:
noise insulation .
– Detach vacuum hose -1- from vacuum unit -2-. Seal opening
6122- .
If vacuum drops:
If pressure does not drop: lkswage es n
o ot g
byV ua
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– Connect hand vacuumoripump
se - VAS 6213- to vacuum unit and antee
generate a vacuumauof 0.6 bar.
th or
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an
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If vacuum drops:
wit
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spec
t to the co

on exhaust gas recirculation cooler
rrectne
Test sequence
s

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form
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vacuum reservoir must first have been checked for leaks

atio
⇒ page 386 .
om
n
c
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– Pull vacuum hose -2- off at central connection of exhaust gas

thi
te

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t.
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for approx. 30 seconds. cop Vo
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Prote
AG.
If vacuum drops:
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Moving to service position .

– Pull off vacuum hose -arrow 2-. Seal opening of vacuum hose
with clean bung from engine bung set - VAS 6122- .
If vacuum drops:
– Connect hand vacuum pump - VAS 6213- to vacuum unit and
generate a vacuum of 0.6 bar.
If vacuum drops:
– Replace exhaust gas recirculation cooler ⇒ page 485 .
2.3 Checking vacuum system for leaks,

“single turbo engine”
⇒ “2.3.1 Checking vacuum hoses leading to non-return valve,
solenoid valve N75 , changeover valve N345 and vacuum reser‐
voir”, page 392
⇒ “2.3.2 Checking vacuum hose to position sender for charge
pressure positioner G581 ”, page 394
⇒ “2.3.3 Checking vacuum hose to vacuumen AG. V
unit
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recirculation cooler”, page 395 olkswag oes
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♦ Set of plugs for engine
ss
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t.
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Prote AG.

AG. Volkswagen AG d
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Caution
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rrectness of i
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nform
ercia
Checking vacuum hoses to non-return valve, charge pressure

m
a
com
ti
control solenoid valve - N75- , exhaust gas recirculation cooler
on in
changeover valve - N345- and vacuum reservoir ⇒ page 392 .
r
te o
thi
s
iva
Checking vacuum hose to position sender for charge pressure
do
r
rp
c
positioner - G581- ⇒ page 394 .
um
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Check vacuum hose to vacuum unit on exhaust gas recirculation
Co
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cooler ⇒ page 395 .
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Check “four-wheel drive” vacuum system for leaks ⇒ page 397 . by c lksw
cted agen
Prote AG.
2.3.1 Checking vacuum hoses leading to non-

return valve, solenoid valve -N75- ,
changeover valve -N345- and vacuum
reservoir
Test sequence
– Pull vacuum hose -1- off at outer connection of charge pres‐
– Pull vacuum hose -2- off at outer connection of exhaust gas
– Connect hand vacuum pump - VAS 6213- to the two valves
one after the other and then generate a partial vacuum of 0.6
bar.
If vacuum drops:
– Replace a leaking valve.

– Seal vacuum hoses -1- and -2- with clean bungs from engine
– Pull vacuum hose -1- off connecting piece -2-.

– Seal connecting piece -2- with a clean bung from engine bung
set - VAS 6122- .

– Connect hand vacuum pump - VAS 6213- to removed AG. Voend
lkswaof
gen AG
agen does
vacuum hose and generate a partial vacuum
Volkswof 0.6 bar. not
y gu
db ara
– Observe pressure gauge of hand vacuum
ris
e pump - VAS 6213- nte
for approx. 30 seconds. utho eo
ra
a c
ss
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un
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an
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If vacuum drops:
itte
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erm
ab
– Locate damage or leaking vacuum hose connection. To do

ility
ot p
this, pull individual vacuum hoses off from respective connec‐

wit
is n
tion and check for leak to connected component.

h re
ole,
spec
– Pull off vacuum hoses -1- and -2- at connector -arrow- and
t to the co
check non-return valve and vacuum hose to exhaust gas re‐

circulation cooler changeover valve - N345- .
rrectne

– Renew non-return valve or leaking vacuum hose.
ss o
– Reconnect all vacuum hoses to valves and to union -arrow-.

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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en
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t.
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Cop py
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393
co Vo
by lksw
cted 2. Vacuum system
agen
Prote AG.
– Pull vacuum hose -arrow- off vacuum reservoir. Seal opening

6122- .
AG. Volkswagen AG d
agen oes
olksw not
– Connect hand vacuum pump - VAS 6213- to pulled-off end dof by
V gu
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h
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– Observe pressure gauge of hand vacuum pump - VAS ss 6213- c
ce
e
nl
pt
du
an
itte
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erm
ab
If vacuum drops:
ility
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– If vacuum hose -1- leaks, renew it.
h re
hole
spec
es, in part or in w
t to the co
– Connect hand vacuum pump - VAS 6213- to vacuum reservoir
and generate a partial vacuum of 0.6 bar.
rrectness of i
l purpos

If vacuum drops:
nf
ercia
orm
– Replace cylinder head cover if it leaks ⇒ page 107 .
m
atio
om
n in
c

or
thi
te
sd
a
– Check following vacuum hoses:

iv
o
r
rp
cu
o
m
♦ Vacuum hose to position sender for charge pressure position‐
f
en
ng
t.
er - G581- ⇒ page 394
yi Co
Cop py
t. rig
♦ Vacuum hose to vacuum unit on exhaust gas recirculation gh ht
yri by
cooler ⇒ page 395
op Vo
by c lksw
cted agen
Prote AG.
♦ Checking vacuum system for leaks, “four-wheel drive”
⇒ page 397
2.3.2 Checking vacuum hose to position

G581-
Test sequence
• Vacuum hoses to non-return valve, charge pressure control
solenoid valve - N75- , exhaust gas recirculation cooler
changeover valve - N345- and vacuum reservoir must first
have been checked for leaks ⇒ page 386 .

– Pull vacuum hose -1- off at central connection of charge pres‐


If vacuum drops:
lkswage es n
o ot g
byV ua
ed ran
– Pull vacuum
thoris
hose -arrow- off position sender for charge
tee pres‐
sures apositioner
u - G581- . Seal opening of vacuum hose or
ac with
clean bung from engine bung set - VAS 6122- .
s
ce
e
nl
pt
du

an
itte
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erm
ab
ility
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wit
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h re
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es, in part or in w
t to the co
If vacuum drops:
rrectness of i

l purpos
– Connect hand vacuum pump - VAS 6213- to potentiometer for

charge pressure positioner - G581- and generate a partial
vacuum of 0.6 bar.
nf
ercia
orm

m
atio
m

o
n in
or c

thi
te
sd
iva
If vacuum drops:
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
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p by
co Vo
by lksw
cted
on exhaust gas recirculation cooler
agen
Prote AG.
Test sequence
• Vacuum hoses to non-return valve, charge pressure control
solenoid valve - N75- , exhaust gas recirculation cooler
changeover valve - N345- and vacuum reservoir must first
have been checked for leaks ⇒ page 386 .

California 2010 ➤ , Caravelle 2010 ➤ , Multivan 2010 ag➤ ,G
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– Pull vacuum hose -2- off at central connectionau of exhaust
th gas e or
ac
recirculation cooler changeover valve - N345-
ss .
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e
nl
pt
du
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ility
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t to the co
rrectness of i
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nf
ercia
or
m
m
atio
m

o
n in
or c
thi
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If vacuum drops:
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull vacuum hose -2- off exhaust gas recirculation cooler.
– Seal opening of vacuum hose with clean bung from engine
If vacuum drops:
– Connect hand vacuum pump - VAS 6213- to exhaust gas re‐
circulation cooler and generate a partial vacuum of 0.6 bar.
If vacuum drops:
– Replace exhaust gas recirculation cooler ⇒ page 492 .

2.4 Checking vacuum system for leaks,

“four-wheel drive”
⇒ “2.4.1 Checking non-return valve and vacuum hoses to valves
N125 and N126 ”, page 398
⇒ “2.4.2 Checking vacuum hoses with non-return valves leading
to valve N125 and N126 ”, page 399
⇒ “2.4.3 Checking vacuum hoses and vacuum switch for rear dif‐
ferential lock F363 ”, page 400

n AG. Volkswagen AG age does
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Caution
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nf

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rm
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atio
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n in
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thi
Check non-return valve and vacuum hoses leading to differential

te
sd
a
lock valve 1 - N125- and differential lock valve 2 - N126-

iv
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rp
cu
⇒ page 398 .
o
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f
en
ng
t.
yi
Check vacuum hoses with non-return valve leading to differential
Co
op py
lock valve 1 - N125- and differential lock valve 2 - N126-
t. C rig
gh ht
yri
⇒ page 399 . p by
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by c lksw
cted agen
Check vacuum hoses and vacuum switch for rear differential lock Prote AG.
- F363- ⇒ page 400 .
– Check following vacuum hoses if necessary:
♦ Vacuum hoses to non-return valve, exhaust flap valve -


vacuum reservoir ⇒ page 386
♦ Vacuum hose to vacuum unit with regulating flap potentiome‐
ter - G584- ⇒ page 388
♦ Vacuum hose to vacuum unit on turbocharger ⇒ page 389
♦ Vacuum hose to vacuum unit on exhaust gas recirculation
cooler ⇒ page 390
♦ Checking vacuum system for leaks, “bi-turbo engine”
⇒ page 384
♦ Checking vacuum system for leaks, “single turbo engine”
⇒ page 391
2.4.1 Checking non-return valve and vacuum

hoses to valves -N125- and -N126-
Test sequence
n AG. Volkswagen A
– Connect hand vacuumolks
wapump
ge - VAS 6213-Gto
doeremoved
s no end of
vacuum hose and
d b generate a partial vacuum of 0.6uabar.
y V tg
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– Observe pressure
tho gauge of hand vacuum pump - VAS 6213-
eo
au ra
for approx.
ss 30 seconds. c
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un

pt
an
d
itte
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If vacuum drops:
rm
ab
pe
ility
– Pull vacuum hose -1- off non-return valve -2-.

ot
wit
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h re
– Seal opening of non-return valve with clean bung from engine

hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos

nform
ercia
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
m
a
com
tion in
– If the non-return valve functions properly, a clear hiss is audi‐

r
te o
thi
ble when vacuum in vacuum hose is released.

s
iva
do
r
If vacuum drops:
rp
cum
fo
en
ng
t.
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– Renew vacuum hose -1- or non-return valve -2- if they leak. Cop py
t. rig
gh ht
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If pressure does not drop: p by
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by c lksw
cted agen
– Push vacuum hose onto non-return valve.Prote AG.
– Remove front left underbody cover ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cover; Removing and in‐
stalling underbody covers .

– Pull vacuum hose -arrow- off connector. Seal opening of vac‐

uum hose with clean bung from engine bung set - VAS 6122- .
If vacuum drops:
– Reconnect vacuum hose to connecting piece and non-return
valve.
wage
e ks s no
Vol t
♦ Vacuum hose with non-return
ed
by valves to differential lock valve
gu
ara
1 - N125- ⇒ page h399
oris nte
e t or
au ac
♦ Vacuum hose swith
s non-return valves to differential lock valve
2 - N126- ⇒ page 399
ce
e
nl
pt
du
an
itte
♦ “Blue” vacuum hose to vacuum switch for rear differential lock
y li
erm
ab
- F363- ⇒ page 400
ility
ot p
wit
♦ “Green” vacuum hose to vacuum switch for rear differential
, is n
h re
lock - F363- ⇒ page 400
hole
spec
Checking vacuum switch for rear differential lock - F363-
es, in part or in w
t to the co
⇒ page 400 .
2.4.2 Checking vacuum hoses with non-return

valves leading to valve -N125- and - rrectness of i
l purpos
N126-
nform
ercia
Test sequence
m
• The non-return valve and vacuum hoses leading to differential

at
om
io
lock valve 1 - N125- and differential lock valve 2 - N126- must

n
c
in t
r
be checked first ⇒ page 398

o
his
ate
do
riv

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or

f
en
g

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t.
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Cop py
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The illustration shows the valve mounting with valves from above.

– Pull vacuum hose -1- leading to differential .lock

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– Connect hand vacuums pump - VAS 6213- to pulled-off vacuum
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– If the non-return valve functions properly, a clear hiss is audi‐
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– Reconnect vacuum hoses to T-piece.
inform
mer
If no hiss is audible:
atio
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– Connect hand vacuum pump - VAS 6213- to differential lock
n
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valve 1 - N125- or to differential lock valve 2 - N126- and gen‐
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– Renew leaking parts.

♦ “Blue” vacuum hose to vacuum switch for rear differential lock
- F363- ⇒ page 400
♦ “Green” vacuum hose to vacuum switch for rear differential
lock - F363- ⇒ page 400
Checking vacuum switch for rear differential lock - F363-
⇒ page 400 .
2.4.3 Checking vacuum hoses and vacuum

switch for rear differential lock - F363-
Test sequence
• The non-return valve and vacuum hoses leading to differential
lock valve 1 - N125- and differential lock valve 2 - N126- must
be checked first ⇒ page 398

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4-cylinder diesel engine (2.0 l kengine,
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– Pull vacuum hose -arrow- off from differential lockorvalve
ise
1- tee
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– Pull vacuum hose -arrow- off from differential lock valve 2 -
l purpos
N126- .
– Connect hand vacuum pump - VAS 6213- in turn to one of the
nform
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removed vacuum hoses and generate a vacuum of 0.6 bar.

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– Reconnect vacuum hoses.
If vacuum drops:
– Pull vacuum hoses -1- and -2- off from vacuum switch for rear
differential lock - F363- -3-. Seal openings of vacuum hoses
with clean bung from engine bung set - VAS 6122- .
If vacuum drops:
– Reconnect vacuum hoses to valves.
Test procedure for vacuum switch for rear differential lock - F363-
– Pull vacuum hose -1- off from vacuum switch for rear differ‐
ential lock - F363- -3-.
– Connect hand vacuum pump - VAS 6213- to connection on
vacuum switch for rear differential lock - F363- and generate
a vacuum of 0.6 bar.

– Lever -1- must then move towards differential lock -arrow-.

If vacuum drops:
– Renew vacuum switch for rear differential lock - F363- ⇒ Rep.
gr. 39 ; Final drive; Assembly overview - final drive .
– Then pull vacuum hose -2- off from vacuum switch for rear
differential lock - F363- -3-.
– Connect hand vacuum pump - VAS 6213- to connection on
vacuum switch for rear differential lock - F363- and generate
a vacuum of 0.6 bar.
If vacuum drops:
– Renew vacuum switch for rear differential lock - F363- ⇒ Rep.
gr. 39 ; Final drive; Assembly overview - final drive .
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Rep. gr.23 - Mixture preparation - injection
agen
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3 Injectors/high-pressure accumulator
(rail)
⇒ “3.1 Removing and installing fuel rail”, page 403
⇒ “3.2 Removing and installing high-pressure lines”, page 406
⇒ “3.3 Removing and installing injectors”, page 412
⇒ “3.4 Testing injectors”, page 417
⇒ “3.5 Testing jammed-open injectors”, page 423
⇒ “3.6 Check pressure retention valve in fuel return line”,
page 425
⇒ “3.7 Checking low pressure fuel system”, page 428
⇒ “3.8 Checking fuel pump delivery rate”, page 429
olkswagen AG
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3.1 Removing
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♦ Torque
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ce
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3. Injectors/high-pressure accumulator (rail) 403

Removing
Vehicles with “bi-turbo engine”:
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– Unclip pressure retention valve -1- and pull off return hoseise d b ara
nte
-2-. uthor eo
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– Release connector -1- from fuel pressure sender - G247- -2-
and pull off.
ss
– Pull left and right cable brackets -3- from high-pressure accu‐
o
cial p
mulator.
inform
mer
atio
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– Release connector -4- from fuel pressure regulating valve -

N276- -3- and pull off.
– Pull off clip -2-.
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– Unscrew bolt -2-, and remove bracket -1-. ut
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– Observe instructions for removing high-pressure lines s
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⇒ page 406 .
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fuel line -2-.
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– Open clip -5- and pull off return hose -4-.

– Unscrew all union nuts -2- using socket - T40055- at injectors
and high-pressure accumulator, and remove high-pressure
lines.
– Place the removed high-pressure lines on a clean cloth.
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– When removing, guide high-pressure wage
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WARNING
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regulating valve - N276- ⇒ Vehicle diagnostic tester.
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– Install high-pressure lines (without tension).
rrectne
– Observe instructions for installing high-pressure lines
⇒ page 406 .
s
– The fuel system must first be filled with fuel before the engine
s o
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is started ⇒ Vehicle diagnostic tester.
inform
mer
Torque settings
atio
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o
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♦ ⇒ “1.2 Assembly overview – connecting pipes (bi-turbo)”, page

t
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282
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3.2 Removing and installing high-pressure
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Special tools and workshop equipment required Prote AG.

♦ Ratchet wrench - V.A.G 1331/1-
♦ Tool insert 17 mm - V.A.G 1331/6-
AG. Volkswagen AG d
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Removing
Caution
The lines must never be bent or tensioned. Tension would oth‐

erwise cause the respective line to break in the long-term.
Note
♦ The fluff-free cloth and the brake cleaner can be ordered in ⇒

ServiceNet; Workshop Equipment; Techno Equipment Cata‐
logue; BMK Consumables .
♦ Whenever work is done on the fuel system, ensure cleanliness
and do the work carefully. The fuel system reacts sensitively
wage
to the ingress of dirt. lks es n
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– Ensure cleanliness at all times. au
th e or
ac
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– Before removing, clean the parts thoroughly all over with brake
ce
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un
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cleaner and fluff-free cloth.
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Preferred order for disconnecting high-pressure lines: cylinder
rm
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Note
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In order to remove the high-pressure line for cylinders 1 and 2 it
is necessary, in “bi-turbo engines”, to remove the upper part of
the bi-turbocharger system ⇒ page 298 .
rrectness of i
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– When loosening the high-pressure lines at the injectors, place

an open-end spanner on the injector connection piece as a
counterhold.
nform
ercia
– Use socket - T40055- to unscrew high-pressure line between

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high-pressure accumulator (fuel rail) and injectors to be re‐
ion in
moved.
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– Place removed parts on a clean, fluff-free surface and cover

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– Use a vacuum-type cleaner to remove dirt from taper seat on
high-pressure accumulator.
– Seal all connections with clean plugs from engine bung set -
VAS 6122- .
Installing
Caution
The lines must never be bent or tensioned. Tension would oth‐

erwise cause the respective line to break in the long-term.

Note
♦ Making use of a setting tool to adjust the high pressure or in‐

jectors (piezo injectors) is not permissible.
♦ Observe cylinder-specific markings if reusing high-pressure
lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ If the taper seal of respective high-pressure line has been
checked for deformation and cracks.
♦ The inside of the line must not be deformed, constricted or
damaged.
♦ Corroded lines should no longer be used.
– When new parts are to be installed, do not remove sealing

caps until installation work has begun.
– Install high pressure line with nothing else between high pres‐
sure pump and fuel rail.
– Install lines without tension.
Sequence
– Fit injection lines from fuel rail to injectors by hand first, tight‐
ening union nuts only hand tight to start with.
If the injection lines cannot be inserted free of stress:
– Undo screws -arrows-.
– Align fuel rail -1- in order that lines can be installed free of
stress.
If the injection lines still cannot be inserted free of stress:
– Loosen bolt for respective clamping plate. n AG. Volkswagen AG do
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– Next install high-pressure line from high-pressure d by V pump to
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– If necessary, loosen bolts of clamping spieces
s a to ensure that ac
injectors can be rotated.
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– Only tighten union nuts on high-pressure line from high-pres‐

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sure pump to high-pressure accumulator by hand.

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doing so, place open-end spanner on connecting piece of in‐

h re
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jector as a counterhold.
spec
t to the co
– To tighten high-pressure lines, use torque wrench - V.A.G

1331- with ratchet - V.A.G 1331/1- and 17 mm socket -
T40055- .
rrectne
– Then, tighten high pressure lines on high pressure accumula‐

tor.
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– Tighten the 4 high-pressure lines in the specified tightening

f in
sequence.
form
mer
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Prote 3. Injectors/high-pressure accumulator (rail)
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In order to position and tighten the union nut on the high-pressureoris tee
pump, the lifting eye must be movable. To ensure this, loosenatheuth or
ac
bolts -4-. ss
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– Fit all clamps -arrows- to the fuel line. Make sure they are
aligned correctly.
– Screw in the bolts -3- of the clips -arrows- approx. 3 turns.
rrectness of i
– Tighten high-pressure line -2- between high-pressure pump
l purpos
and high-pressure accumulator first at high-pressure pump

and then at high-pressure accumulator.
nf
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– Tighten nuts -1- of fuel high-pressure fuel line.
rm
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– Tighten high-pressure accumulator (fuel rail) bolts again.

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– Tighten union nuts of all new injection lines using torque

wrench - V.A.G 1331- and socket bit - T40055- .
– Firmly screw lifting eye in ⇒ page 41 .


connections.
– Attach fuel return line and press the two clips downwards as Volkswa
far as they will go -arrows-. swa
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– Engage pressure retention valve in retainer provided on the
cylinder head cover.
– Bleed the fuel system with the ⇒ Vehicle diagnostic tester.

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After renewing the injectorsise(piezo injectors) “perform adaptationuaran
d b
of the correction values”th⇒o Vehicle diagnostic tester. When doing
r tee
or
this, select “Reading s/s adapting” correction values.
au ac
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– Filling fuel system ⇒ Vehicle diagnostic tester.
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– Check high pressure lines and connections for leaks. To do
ility
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this, allow engine to run at idle for 5 minutes without pressing
wit
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– Then, switch the engine off again.
spec
es, in part or in w
– Check the complete fuel system and return line connections
t to the co
for leaks.
– Wipe the connections with a clean cloth and check whether
rrectness of i
there is fuel on the cloth.
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• Renew the affected component if leakage still occurs after

tightening to the correct torque.
nf
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• Tightening threaded connections further is not permissible. orm

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– Then check high-pressure section of fuel system again for

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If there is still air in the fuel system, the engine can change to cted agen
Prote AG.
emergency running mode during road test. Switch off engine and
clear event memory ⇒ Vehicle diagnostic tester. Then continue
with a road test.
Torque settings
3.3 Removing and installing injectors


equipment required
♦ Tapered roller bearing pull‐
er - T10055-
♦ Assembly sleeve - T10377-
1331-
♦ Ratchet wrench - V.A.G
1331/1-
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♦ Tapered roller bearing puller - T10402-

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Caution
• Do not interchange removed injectors (piezo injectors).

• When a new injector is installed, the adaptation value for
the new injector must be written in the engine control unit
⇒ page 417 .

Removing
– Pull off connector -1- at the injectors to be removed.
AG. Volkswagen AG d
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Disconnecting fuel return lines hole
spec
es, in part or in w
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Caution
rrectness of i
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-arrow B-.
Note
Maintain cleanliness. No dirt must be allowed to get into the dis‐

connected fuel return lines or the open connections on the injec‐
tors under any circumstances.
– Unbolt high-pressure line ⇒ Item 18 (page 375) between fuel

rail and injectors to be removed.
– Unscrew bolts ⇒ Item 18 (page 375) for injectors to be re‐
moved beneath noise insulation ⇒ Item 10 (page 94) . Lift out
and fold up noise insulation to do this.

– Place puller - T10055- with adapter - T10055/1- in position as

shown and pull injector out downwards with tapping move‐
ments.
Installing
AG. Volkswagen AG d
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– The 7-digit adaptation valuesss-1- (details in illustration are only
a c
an example) are marked separately on each injector. Read off
ce
le
un
pt
and note down this value before installing new injectors.
an
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Important instructions for installing injectors
rm
ab
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ility
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• When removing and installing, always renew the following
wit
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components and seals/O-rings: “copper seal”, “O-ring for in‐
h re
hole
jector bore”, “O-ring for injector return connection”.
spec
es, in part or in w
• Used injectors may only be re-installed on the same cylinder.
t to the co
• Make sure that the injectors and the installation area are clean
before installing.
rrectness of i
• The injectors must be completely undamaged.
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• Lubricate all O-rings with diesel before installing.

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If a used injector is being re-installed:

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– To remove the old copper seal from the injector, carefully

ion in
clamp the copper seal in a pair of pliers so the copper seal is

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just prevented from spinning. Then carefully pull and twist the
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injector out of the copper seal by hand.

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– Clean injector tip and sealing surface.

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4-cylinder diesel engine (2.0 l engine, common rail) - Edition
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– Fit new copper sealing ring -1- on injector -2- with help riseof as‐ nte
tho eo
sembly sleeve - T10377- . Use “narrow” side of assembly
s au ra
c
sleeve - T10377- for this. s
ce
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un
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– Carefully slide new O-ring over fuel return connection to avoid
an
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damaging O-ring.
erm
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– Clean sealing surface of injector in cylinder head and injector
wit
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shaft.
h re
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spec
WARNING
t to the co
Only cleaning set - VAS 6811- may be used for cleaning the
sealing surface of the injector bore.
rrectne
For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
ss
⇒ operating manual provided with the cleaning set - VAS
o
cial p
f
6811- .
inform
mer
atio
om
n
c
i
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– Renew seal -1- for injector bore using assembly sleeve -
thi
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T10377- .
t
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– Push clamping plate onto injectors.
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– Coat injector O-rings with assembly oil, engine oil or diesel Cop py
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– Insert injectors with clamping plate into injector bores without
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– Check O-rings for damage. Replace damaged O-rings.

connections.


AG. Volkswagen n AG do
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– Install high-pressure ot g
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Note
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After renewing one or more injectors, the injector delivery cali‐
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bration values for the new injectors must be written into the engine
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control unit using ⇒ Vehicle diagnostic tester ⇒ page 417 .
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Injectors must be tested in this sequence!

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⇒ page 417
• Checking pressure retention valve of fuel return line
⇒ page 425
• Checking return flow rate of injectors with engine running
⇒ page 418
• Checking return flow rate of injectors at starter speed
⇒ page 421
Checking adaptation of “injector delivery calibration values”
The function “injector delivery calibration” serves to correct the
injection rates for each cylinder of a common rail system individ‐
ually across the entire map range.
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each injector. They may con‐
sist of letters and/or numbers (ASCII code).

Table of characters for reading the characters on the injector

When a new injector is installed, the adaptation value for the new
injector must be written to the engine control unit.
When the engine control unit is renewed, the “injector delivery
calibration values” must be written into the new engine control
unit.
The work procedure for the adaptation is described in ⇒ Vehicle
diagnostic tester.
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Additionally check that the “injector delivery calibration” values Volksw not
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Checking return flow rate of injectors with engine running
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WARNING
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The engine must not be started with the pressure retention
h re
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valve removed as the injectors will otherwise be damaged.
spec
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– Separate hose connection -2- behind pressure retention valve
-1- of fuel return lines.
rrectne
– Seal open fuel line return connection with a plug.
ss
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the total amount of return flow.
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– Start engine and allow to idle for 2 minutes.
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Checking return flow rate of individual injectors

♦ Injection rate comparison meter - V.A.G 1348-
♦ 4 lengths of hose must be made up in the workshop to fit return
line connections on injectors.
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high (compared to the
other injectors), that injector is probably defective.
The other 3 injectors may also be defective.
– Switch off the engine.
– Clean all return line connections with, for example, commer‐
cially available degreaser before removing them.
– Dry all cleaned parts.

– With engine switched off, separate fuel return line -2- behind
pressure retention valve -1-
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connected fuel return lines or the open connections on the injec‐yV
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Do not accelerate the engine during the test. Engine must be
idling all the time.
Running the engine at higher speeds with the return lines dis‐
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connected will cause damage to the injectors.
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– When the engine is warm and running at idling speed the re‐
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– If one injector has a significantly higher return flow rate than

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the others it must be renewed ⇒ page 412 .

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– Apply a thin coat of diesel fuel to new O-rings on return-line Prote AG.
connections.


– Checking fuel system for leaks ⇒ page 378 .
Checking return flow rate of injectors at starter speed
If the engine cannot be started, the return flow rate of the injectors
can also be checked at starter motor speed.
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♦ Two injection rate comparison meters - V.A.G 1348- are re‐
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♦ 4 lengths of hose must be made up in the workshop to fit return
h re
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line connections on injectors.
spec
Each injector normally has a relatively low return flow rate. If the
t to the co
return flow rate at one injector is relatively high (compared to the
other injectors), that injector is probably defective.
– Clean all return line connections with, for example, commer‐ rrectne
cially available degreaser before removing them.
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– With engine oswitched
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auth To do this, press both clips downwards eo
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-arrow B-.
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his
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This prevents the fuel from being injected during the attempt at
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– Fit hose lines onto return line connections of all 4 injectors.

– Insert the 4 hose lines into the injection rate comparison meter
- V.A.G 1348- .
– Operate starter three times. Wait approx. 20 seconds each
time after operating starter to prevent it from overheating.
• Return flow rate specification: 0 ml
– If fuel escapes from an injector, that injector has to be re‐
newed.
– Re-attach connector of fuel pressure sender - G247- .
– Use a fault read-out device to delete event memory entry.
– Renew O-rings of all return line connections. Carefully slide
new O-ring over fuel return connection to avoid damaging O-
ring.
connections.


– Checking fuel system for leaks ⇒ page 378 .
AG. Volkswagen AG d
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3.5 Testing jammed-open injectors

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♦ Tool insert, 17 mm - V.A.G 1331/6-
♦ Plug - T40204-
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♦ The fluff-free cloth and the brake cleaner can be ordered in ⇒

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and do the work carefully. The fuel system reacts sensitively co Vo
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– Delete event memory entry with ⇒ Vehicle diagnostic tester.
– Before removing, clean the parts thoroughly all over with brake
cleaner and fluff-free cloth.
– Ensure cleanliness at all times.
– Check one cylinder after the other.
Begin with cylinder 1.

4-cylinder diesel
gen AG
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Volkswag(2.0
en AGl engine, common rail) - Edition 08.2016
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b rail. Also, loosen the ara
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– Seal the open connection with screw plug - T40204- .
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• The electrical connector of the respective injector to be
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checked must remain connected.
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Note
♦ When the correct injector has been located, there will be no
rrectne
fault stored regarding “positive regulation deviation”.
♦ Other fault messages may possibly be stored in the memory.
ss
These new event memory entries must be taken into consid‐
o
cial p
f i
eration (follow-on faults).
nform
mer
atio
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– After road test, read out event memory. If there is an event

o
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memory entry regarding “positive control deviation” again, re‐
i
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peat the steps for all connections until there are no longer any
te
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event memory entries after a road test.

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Note installation instructions for all injector lines.
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– Tighten union nuts of high-pressure lines hand-tight. Make
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– Install high-pressure lines ⇒ page 406 .
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3.6 Check pressure retention valve in fuel

return line
WARNING
The engine must not be started with the pressure retention

valve removed as the injectors will otherwise be damaged.

♦ Fuel return system tester - VAS 6330-
The pressure retention valve maintains a residual pressure (con‐

trol volume) of approx. 10 bar in the return line.
This residual pressure is required for the control function of the
piezo injectors.
– Clean all return line connections of 1st cylinder with commer‐
cially available degreaser, for example, before removing them.

AG. Volkswagen A
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– Dry return line connection of 1st cylinder.
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nl
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Disconnecting fuel return lines hole
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– With engine switched off, carefully pull return line connections p by
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AG.
-arrow B-.
Note

connected fuel return lines or the open connections of the injector.

– Fit fuel return system tester - VAS 6330- between return line
connection on injector and return line.
– Start engine and run at idling speed for approx. 60 seconds.
– Check pressure on pressure gauge.
♦ Specification: 8 to 14 bar
If the value does not match the specification, fit a new pressure
retention valve.
Note
♦ The pressure retention valve may only be renewed completely

together with the fuel return lines.
♦ Carry out the measurement close to the pressure retention
valve in the fuel return line of cylinder 4.
– Check O-rings for damage. Replace damaged O-rings.

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– tho has been pushed
After fuel returnauline on completely, press or
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3.7 Checking low pressure fuel system
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Test conditions
• Battery voltage at least 12.5 V.
• Fuel filter OK.
• Fuel tank at least 1/2 full.
• Ignition switched off
Checking holding pressure
– Wrap a clean cloth around connection before opening fuel
system, and then carefully loosen connection to release pres‐
sure.

– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable

-adapter- to fuel supply line -1-. Connect other adapter -3- from
K-Jetronic pressure tester - V.A.G 1318- to open connection
on high-pressure pump.
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– Turn the shut-off tap on K-Jetronic pressure tester - V.A.G
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1318- to “Open” position if necessary.
spec
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– Carry out basic setting. rrectness of i
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– The fuel pumps start up.

– Run fuel pumps until highest fuel pressure has built up.
nform
ercia
• Specification: at least 3.5 bar

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If specification is not obtained

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Check threaded connection between pressure gauge and fuel line

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Check fuel pump delivery rate ⇒ page 429 .
AG.
Check fuel system for leaks.
3.8 Checking fuel pump delivery rate


♦ K-Jetronic pressure tester - V.A.G 1318- with adapter

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Test conditions
• Battery voltage at least 12.5 V
ss o
• Fuel filter OK.
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• Fuel tank at least 1/2 full.
mer
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• Ignition off
n
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Testing quantity of fuel delivered

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– Allow fuel pumps to run for 10 seconds and then
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• Specified amount in 10 seconds: at least 400 ml
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If the minimum delivery rate is not achieved, the following faults
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♦ 10 seconds not reached
♦ Fuel lines have been crushed
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♦ Fuel filter is blocked
l purpos
♦ Fuel pumps defective: test ⇒ Rep. gr. 20 ; Fuel pump
nform
ercia
♦ Check fuel system for leaks.

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4 Air filter
⇒ “4.1 Assembly overview - air filter housing”, page 432
⇒ “4.2 Removing and installing air filter housing”, page 434
4.1 Assembly overview - air filter housing
1 - Air mass meter - G70-

⇒ page 443
2 - O-ring
3 - Air filter upper part
4 - Filter element
5 - Air filter lower part
6 - Rubber mounting
❑ Clipped into lower part
of air filter
7 - Holder
❑ Fitted onto wheel hous‐
ing
8 - Pop rivet
❑ Use blind-rivet gun -
VAS 5072- to renew.
9 - Water drainage pipe
❑ Is not removed and in‐
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❑ To remove, the air filter y Vo lks ot g
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⇒ page 433
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10 - Holder
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❑ Fitted onto longitudinal

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11 - Rubber mounting
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❑ Clipped into lower part of air filter

12 - Bolt
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❑ 8 Nm
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13 - Air guide
14 - Fastener
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15 - Mounting for air duct

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❑ Fastened to lock holder with spreader clip ⇒ Item 14 (page 432)

on in
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❑ Fitting position on lock holder ⇒ page 433

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17 - Connecting pipe
❑ From crankcase breather/cylinder head cover
❑ Vehicles with “bi-turbo engine”: Note installation position of connecting hose ⇒ page 433
❑ Vehicles with “single turbo engine”: Note installation position of connecting hose ⇒ page 434
19 - Intake manifold pressure sender - G71-
20 - Bolt
❑ 3.5 Nm
Air duct on lock holder

– Use spreader clip -2- to fasten air duct -3- to lock holder -1-.
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Installation position of connecting hose at turbocharger

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4. Air filter 433

Installation position of intake hose at turbocharger

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4.2 Removing and installing air filter hous‐
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Removing
– Release locking lug -2-.
– Pull off intake hose -1- from air filter housing.
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– Release and pull off water drainage pipe -3- on air filter hous‐ cop Vo
by lksw
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4. Air filter 435

– Carefully pull out air filter housing -2- from guides.

Installing
Torque settings
♦ ⇒ “4.1 Assembly overview - air filter housing”, page 432
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5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 437
AG . Volkswage
⇒ “5.2 Removing and installing intake
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⇒ “5.3 Removing and installinged
b throttle valve module J338 with aran
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throttle valve potentiometer
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V157 ”, page 442 ss a ra
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5.1 Assembly overview - intake manifold

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1 - Throttle valve module -
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J338- with throttle valve poten‐
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tiometer - G69- and intake
ole,
spec
manifold flap motor - V157-
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⇒ page 442
2 - Bolt
rrectne
❑ 10 Nm
s
3 - Bolt
s o
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❑ 10 Nm
inform
mer
4 - Fuel lines
atio
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5 - Bolt
c
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❑ 8 Nm
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8 - Tube
❑ From exhaust gas recir‐
culation cooler
9 - Seal
11 - Oil dipstick
12 - Holder
5.2 Removing and installing intake manifold

5. Intake manifold 437


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Removing
– Remove fuel rail ⇒ page 403 .
rrectness of i
– Pull connector off glow plugs ⇒ page 502 .
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– Detach coolant hose at cylinder head cover -arrows-.

– Open clamps -1- and -4-. Remove fuel supply line -3- and fuel
return line -2-.
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– Open bracket -1- and remove coolant hose from fuel lines to‐
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gether with clip -2-.
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– Remove fuel supply and fuel return line hoses on right-hand
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– Open clip -4- and pull off fuel supply line -3-.
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– Detach line -2- from clip -1-.

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– Open bracket -7- and detach coolant hose -6-.

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– Unscrew bolt -4- from oil dipstick -3-.

– Unscrew bolt -2-, and remove bracket -1-.
– Remove fuel line.
5. Intake manifold 439

– Bear in mind different bolt lengths for pipe -2-.

– Unscrew bolts -1- from pipe -2-.

– Remove pipe -2- with gasket -1-.
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– Detach bracket -arrow- with wiring
thor harness on left of intake
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manifold. au or
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– Release all connectors -1- and pull off from injectors (piezo
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injectors).
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– Unscrew bolts (qty. 10) from intake manifold
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– Make sure that gasket -2- is correctly seated in intake mani‐

fold.
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441
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5. Intake manifold
– Position pipe -2- together with gasket -1- and bolt -3-. Screw
in bolt hand-tight to do this.
– Install high-pressure lines (without tension).
– Observe instructions for installing high-pressure lines
⇒ page 406 .
– The fuel system must first be filled with fuel before the engine
is started ⇒ Vehicle diagnostic tester.
Torque settings
wage oes
Volks not
5.3 Removing and installing throttle valve by gu
ara
ed nte
ris
module - J338- with throttle valve poten‐ tho eo
au ra
c
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tiometer - G69- and intake manifold flap
ce
le
un
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motor - V157-
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– Unscrew bolts -arrows- then remove throttle valve module -
J338- -4-.
Installing
Torque settings

6 Senders and sensors

⇒ “6.1 Removing and installing air mass meter G70 ”, page 443
⇒ “6.2 Removing and installing fuel pressure regulating valve
N276 ”, page 444
⇒ “6.3 Checking fuel pressure regulating valve N276 ”,
page 447
⇒ “6.4 Removing and installing fuel pressure sender G247 ”, page
448
⇒ “6.5 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 450
6.1 Removing and installing air mass meter

- G70-

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6. Senders and sensors 443

Removing
– Unplug electrical connectors -3-.
– Remove air mass meter - G70- -1-.
Installing
To ensure the proper function of the air mass meter - G70- , it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter - G70- and affect the air mass value.
This would lead to loss of power, since a smaller injection
quantity is calculated.
♦ Always use Genuine part for air filter element. AG. Volkswagen AG d
agen oes
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– Check for salt residue, dirt and leaves inrisair
e mass meter and
d ara
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air intake hose (engine intake side). ut ho eo
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– Check intake port for dirt as far as the air filter element. If con‐
s
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tamination is found, remove salt residues, dirt and leaves from
pt
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top and bottom part of air filter housing by rinsing out or using
itte
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♦ ⇒ “4.1 Assembly overview - air filter housing”, page 432
hole
spec
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6.2 Removing and installing fuel pressure
regulating valve - N276- rrectness of i
The fuel pressure regulating valve is located in the fuel rail. The
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valves ensure that pressure is constant in the fuel rail and in the
injector lines (fuel high pressure circuit).
nf
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If pressure is too high in the fuel high pressure circuit, the regu‐
or
lating valve will open. A small amount of fuel from the fuel rail will
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If pressure is too low in the fuel high pressure circuit, the regulat‐
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Fuel pressure regulating valve - N276- must be renewed each Prote
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time after removing.

Caution
Read through the rules for cleanliness and the instructions for
working on the fuel system ⇒ page 10 .
Follow these instructions before starting work and while work‐
ing on the fuel system.
– Clean threaded area around the regulating valve with com‐

mercially available degreaser, for example, before removing
it. Do not allow dirt to get into the hole of the high-pressure
accumulator (fuel rail) in any circumstances.
Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
– Dry fuel pressure regulating valve - N276- .

– Remove fuel rail ⇒ page 403 .
– Clamp high-pressure accumulator (fuel rail) in a vice with pro‐
tective jaws.
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– Counterhold at 36 mm hexagon -3- and loosen 30 mm union

nut -2-. Then unscrew regulating valve by hand.
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off fuel rail bore immediately with a suitable plug to prevent
dirt from entering.
Installing
WARNING
regulating valve - N276- ⇒ Vehicle diagnostic tester.
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♦ The fuel pressure regulating valve - N276- has a deformable
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♦ Check that sealing surfaces (deformable sealing lip) and

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spec
♦ Check the sealing surface of the high-pressure accumulator

es, in part or in w
hole as well.
t to the co
♦ Thread on fuel pressure regulating valve - N276- must be free

of oil and grease.
rrectness of i
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4-cylinder
Volksw diesel engine (2.0 l engine,
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y ua
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– Renew oil seal -1-. tho or
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– Tighten union nut -2- by hand. s
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Connector connection piece must point vertically upwards.
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spec
– Align fuel pressure regulating valve - N276- so that connector
es, in part or in w
t to the co
connection piece points vertically upwards.
– Counterhold at housing hexagon -3- and tighten union nut
-2-.
rrectness of i
– Install high-pressure accumulator (fuel rail) ⇒ page 403 .
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– Bleed fuel system ⇒ Vehicle diagnostic tester.
nform
ercia
– After mounting, leave engine running at moderate speed for a

few minutes and then switch off again.
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– Check fuel system for leaks.
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– Read event memory again.
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Torque settings
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6.3 Checking fuel pressure regulating valve

- N276-
♦ Engine plug set - VAS 6122-
♦ Test equipment - V.A.G 1348/2B-

WARNING

– Open clip -4- and pull off fuel supply line -3-.
– Use plug -1- from engine bung set - VAS 6122- to seal open
return line connection.
– Connect fuel return line -2- to suitable hose -3-.
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– Hold end of this hose -1- in meter - V.A.G 1348/2B- -2- to

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measure return flow rate.

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– Start engine and run at idling speed for 30 seconds.

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• Specified amount in 30 seconds: 90 to 110 ml

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spec
es, in part or in w
If the specification is not attained, the fuel pressure regulating

t to the co
valve - N276- is defective.

rrectness of i
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6.4 Removing and installing fuel pressure

m
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sender - G247-
ion in
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4-cylinder diesel engine (2.0 l engine,AGcommon
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♦ Torque wrench - V.A.G 1332- ed
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Fuel pressure sender - G247- is located in high-pressure accu‐
mulator. It measures the fuel pressure and sends a voltage signal
l purpos
to the control unit for direct diesel injection system - J248- .

In the event of sender failure, pressure regulation is controlled
nf
ercia
o
using a map from the engine control unit. In back-up function, the
rm
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atio
maximum engine speed is limited to approx. 3000 rpm.
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Removing
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Caution
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Read through the rules for cleanliness and the instructions for C py
ht. rig
working on the fuel system ⇒ page 10 . rig ht
py by
co Vo
by lksw
Follow these instructions before starting work and while work‐ cted agen
Prote AG.
ing on the fuel system.
– Clean threaded area around the regulating valve with, for ex‐
ample, commercially available degreaser before removing it.
Do not allow dirt to get into the hole of the high-pressure ac‐
cumulator (fuel rail) in any circumstances.
Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
– Dry fuel pressure sender - G247- .

– Release connector -1- from fuel pressure sender - G247- -2-

and pull off.
– Unscrew fuel pressure sender - G247- using a commercially
available extended socket.
– Use suction device to extract dirt from high-pressure accumu‐
lator bore (threads and sealing surface). Do not use any
mechanical tools to do this.
Note
Seal off fuel rail bore immediately with a suitable plug to prevent
dirt from entering.
Installing
Note
♦ Check that sealing surfaces (deformable sealing lip) and

threads on fuel pressure sender - G247- are undamaged.
♦ Check the sealing surface of the high-pressure accumulator
hole as well.
♦ The thread of the fuel pressure sender - G247- is coated with
a lubricating lacquer. The thread must therefore be free of oil
and grease.
– Tighten fuel pressure sender - G247- by hand.

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– Tightening sender. Volksw not
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– Bleed fuel system ⇒ Vehicle ris diagnostic tester. nte
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– After mounting, leave sengine running at moderate
s speed for a c
few minutes and then switch off again.
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– Check fuel system for leaks.

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spec
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Torque settings
rrectness of i
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6.5 Removing and installing exhaust gas

pressure sensor 1 - G450-
nform
mercia
a
com
tion in
6.5.1 Removing and installing exhaust gas

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pressure sensor 1 - G450- , vehicles

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with front-wheel drive

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⇒ “6.5.2 Removing and installing exhaust gas pressure sensor 1 Cop py
ht. rig
G450 , vehicles with four-wheel drive”, page 452 rig ht
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Special tools and workshop equipment required Prote
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Removing
Note
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The exhaust pressure sensor 1Vo-lkG450- is located at the front
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the left on the engine. sed by ua
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– Detach connector
ss of -4-
exhaust pressure sensor 1 - G450-
a ac
-3- and unscrew bolt -1-.
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The hoses remain connected to exhaust gas pressure sensor 1 -

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G450- .
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– Pull clip -2- out of holder.

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Installing
form
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– If exhaust gas pressure sensor 1 - G450- is renewed, carry out

i
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adaption ⇒ Vehicle diagnostic tester.

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Torque settings
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6.5.2 Removing and installing exhaust gas
b ara
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pressure sensor 1 - G450- , vehicles
t
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ss
with four-wheel drive
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⇒ “6.5.1 Removing and installing exhaust gas pressure sensor 1
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G450 , vehicles with front-wheel drive”, page 450
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Removing
Note
The exhaust pressure sensor 1 - G450- is located in the holder

on the front axle at the rear on the left.
– Remove clips -arrows- and pull off hoses.

– Carefully cut through cable tie -5-.
– Remove bolt -1- and remove exhaust gas pressure sensor 1
- G450- -2-.
Installing
– Secure cables -4- and -6- of the two exhaust temperature
senders with a new cable tie -5-.
– If exhaust gas pressure sensor 1 - G450- is renewed, carry out
adaption ⇒ Vehicle diagnostic tester.
Torque settings

7 Engine (motor) control unit

⇒ “7.1 Removing and installing engine (motor) control unit J623
”, page 453
7.1 Removing and installing engine (motor)

control unit - J623-
Removing
– If engine control unit - J623- was renewed, learnt values must
be reset ⇒ Vehicle diagnostic tester, 01 - Systems capable
of self-diagnosis , 01 - Diesel direction injection
and preglow system EDC 17 , 01 - Engine electronics
functions , Bringing into operation .
Note
If the adaption values of the injectors cannot be read from the old
(defective) engine control unit - J623- , the adaption values must
be entered in the new engine control unit - J623- manually and
adjusted. wage
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– Remove battery tray ⇒ Electrical system; Rep. gr. ris 27 ; Battery;
e nte
Removing and installing battery tray . utho eo
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– Remove electronics box cover ⇒ Electrical system; Rep. gr.
ce
e
nl
pt
97 ; Relay carrier, fuse carrier, electronics boxes; Removing
du
an
itte
and installing electronics box .
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ility
– Disconnect connectors -2- and -3- from engine control unit -
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J623- -1-.
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hole
spec
– Pull engine control unit - J623- -1- in -direction of arrow- out of
es, in part or in w
electronics box -2-.
t to the co
Installing
rrectness of i
Install in reverse order of removal.
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nform
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at
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ion
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7. Engine (motor) control unit 453

8 High-pressure pump
⇒ “8.1 Removing and installing high-pressure pump”, page 454
8.1 Removing and installing high-pressure

pump
Caution
AG. Volkswagen AG d
agen
♦ Risk of irreparable damage
olks to high-pressure pump ifot al‐
w es n o
yV gu
lowed to run dry.sed b ara
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or
♦ The high pressure
ut
h
pump must be filled with fuel before the or
ac
sa
engine is started the 1st time ⇒ Vehicle diagnostic tester.
s
ce
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(It is important not to allow the high-pressure pump to run

un
pt
while still empty.)
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♦ Tapered roller bearing pull‐
er - T40064-
rrectne
♦ Press tool - T40064/1-
ss
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1331-
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♦ Pliers - 3314-
Removing
Vehicles with bi-turbo engine:
– Remove exhaust gas recirculation cooler ⇒ page 485 .
– Removing toothed belt from camshaft and high-pressure
pump ⇒ page 122 .
olksw
– Unclip pressure retention
wage
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V
-1- and dpull
agen AG
oes off return hose
-2-. Volks not
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– Pull cable guide -3- from fuel rail.

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8. High-pressure pump 455


fuel line -2-.
– Disconnect connectors -1- and -3-.

– Remove supply hose -2- and return hose -4-.
AG. Volkswagen AG d
agen oes
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Note
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A small hand-held mirror is required to unscrew and insert nut s
-3-.
s o
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– Unscrew bolts -2- and remove toothed belt pulley.
– Hold hub of high-pressure pump with counterhold - T10051-

and unscrew nut -1-.
lkswage es n
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– Position puller - T40064- with thrust piece - oT40064/1-
ir se
d
and pin ran
tee
- T40064/2- as shown and pull hub off high-pressure
auth pump. If or
ac
necessary, counterhold with an open jaw ss spanner (24 mm).
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– If high-pressure pump is to be renewed, unscrew bolts -4- from
l purpos
bracket.
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8. High-pressure pump 457

– Unscrew bolts -arrows- of high-pressure pump.

– Remove high-pressure pump.
Installing
AG. Volkswagen AG d
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Vol Caution
ksw
oes
not
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After new or removed
ut
hor
parts such as the fuel filter or fuel lines eo
have been fitted, the high-pressure pump must be filled with
a ra
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fuel before the engine is started for the first time. It is essential
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not to allow the high-pressure pump to run while still empty.
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– Install toothed belt ⇒ page 122 .
l purpos
– Install high-pressure lines ⇒ page 406 .
nform
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Torque settings
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page 482
at
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Prote AG.

26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 459
⇒ “1.2 Removing and installing front exhaust pipe”, page 462
⇒ “1.3 Separating exhaust pipes, silencers”, page 464
⇒ “1.4 Check exhaust system for leaks”, page 465
⇒ “1.5 Aligning exhaust system free of stress”, page 465
⇒ “1.6 Installation position of clamp”, page 466
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencers, vehicles compliant with
EU 4 standard”, page 459
⇒ “1.1.2 Assembly overview - silencers, vehicles compliant with
EU 5 standard”, page 461
1.1.1 Assembly overview - silencers, vehicles compliant with EU 4 standard
❑ 8 Nm
2 - Seal n AG. Volkswagen AG do
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❑ Observe installation po‐ yV
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3 - Front exhaust pipe with cat‐
ce
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un
pt
alytic converter
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❑ Handle carefully to
rm
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avoid damage.
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• Transport shock-free.
h re
hole
spec
• Do not kink flexible hose.
es, in part or in w
t to the co
• Do not stretch flexible hose.
⇒ page 462
rrectness of i
4 - Double clamp
l purpos

nform
ercia
tion ⇒ page 466 .

m
❑ 31 Nm
com
tion in
r
5 - Mounting
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❑ Align free of tension

fo
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⇒ page 465
n
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7 - Bolt
❑ 60 Nm
1. Exhaust pipes, silencers 459

8 - Rear silencer
❑ For repairs, renew individually.
❑ Note different versions ⇒ ETKA (Electronic Parts Catalogue)
❑ Separating front and rear silencers ⇒ page 464 .
❑ Align free of tension ⇒ page 465
Volkswa
9 - Separation point agen
AG. gen AG
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❑ For repair cases ed byV gu
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❑ During production, front and rear silencers are installed
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as a single component. For repair work, e o the front
and rear silencers are each supplied with a double
ss a clamp. ra
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11 - Mounting
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12 - Mounting for front exhaust pipe

nform
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at
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c
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460 Rep. gr.26 - Exhaust system

1.1.2 Assembly overview - silencers, vehicles compliant with EU 5 standard
1 - Mounting
⇒ page 465
2 - Bolt
❑ 23 Nm
3 - Mounting
⇒ page 465
4 - Bolt
❑ 23 Nm
❑ 8 Nm
6 - Seal
sition
7 - Front exhaust pipe with cat‐
alytic converter
❑ Note different versions
⇒ ETKA (Electronic
Parts Catalogue)
❑ Handle carefully to
avoid damage. wage
es ks not
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• Do not kink
au flexible hose.
th ra
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⇒ page 462
erm
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❑ 45 Nm
es, in part or in w
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9 - Double clamp
rrectness of i

❑ 31 Nm
l purpos
10 - Mounting
nf
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11 - Mounting
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13 - Rear silencer
❑ For repairs, renew individually. lkswage es n
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❑ Note different versions ⇒ ETKA (Electronic
ir se
d b Parts Catalogue) ran
o tee
❑ Separating front and rear silencers
auth ⇒ page 464 . or
ac
ss
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le
un
pt
14 - Separation point
an
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❑ For repair cases rm
ab
pe
ility
❑ During production, front and rear silencers are installed as a single component. For repair work, the front
ot
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and rear silencers are each supplied with a double clamp.
h re
hole
spec
es, in part or in w
15 - Resonator
t to the co
rrectness of i
l purpos
nform
mercia
1.2 Removing and installing front exhaust
a
com
tion in
pipe
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Removing
Note
Handle carefully to avoid damage.

– Undo clip -1- between particulate filter and exhaust pipe with
»small« tool -2-.
– Turn clip -2- downwards when mounting -arrow B-.

– Disconnect connector -5- and remove -arrow A-.
– Cut cable tie -4- and remove wiring harness from retainer -1-.
AG. Volkswagen AG d
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or eo
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– Loosen nutsss -1- and push clamp forwards -arrow-. c
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– Remove front exhaust pipe.

pt
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Installing
nform

mercia
– Use new clips and gaskets.

a
com
tion in
– Align double clamp -2- between front silencer -1- and rear si‐
r
te o
thi
lencer -3 - when installing.

s
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• The distance -a- must be approx. 5 mm.

um
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– Tighten threaded connections -4- of double clamp -2- in this
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1.3 Separating exhaust pipes, silencers

♦ Chain-type pipe cutter - VAS 6254-
AG. Volkswagen AG d
agen oes
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♦ or body saw - VAS 6780- d by V gu
ara
rise nte
tho eo
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pt
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WARNING
nform
ercia
To avoid injury from metal shavings, wear eye protection and

m
at
protective clothing.
om
ion
c
in t
or
his
ate
do
riv
– Mark cutting location -a- = 144 mm on front silencer exhaust

p
cum
pipe -1-.
for
en
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t.
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– Cut through exhaust pipe at right angles at separating point
Co
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position.
– Checking exhaust system for leaks ⇒ page 465 .
– Align exhaust system free of stress ⇒ page 465 .
1.4 Check exhaust system for leaks

– Start engine and allow it to run at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points. Vof connection between exhaust
olkswagen AG
manifold and thekscylinder
w agen
AG head, between doeturbocharger
s no and
front exhaust
by pipe to make sure there are no leaks.
Vol t gu
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– Repairthany
or leaks found. tee
or
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1.5 Aligning exhaust system free of stress
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nform
mercia
a
com
tion in
r
te o
thi
• The exhaust system must be aligned when cold.

s
iva
do
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rp
cum
Centre silencer
fo
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t.
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– Loosen threaded connections of clamps.
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rig
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– Push centre silencer -2- towards front, until dimension -a- of
py by
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5 mm has been attained on front bracket -1- and dimension
by lksw
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-b- of 7 mm on rear bracket -3-.
AG.
– Tighten front clamp.

Rear silencer
– Push rear silencer -2- towards front, until dimension -a- of
9 mm has been attained on front bracket -1- and dimension
-b- of 11 mm on rear bracket -3-.
– Tighten rear clamp.
Align end exhaust pipes

– Align rear silencer so that distance -a- between attaching parts
and exhaust tailpipes is the same on the right and left.
– Align rear silencer so that the distance -b- between attaching
parts is parallel to the exhaust tailpipes.
– Loosen mountings of rear silencer in order to align it.
1.6 Installation position of clamp

Clamp installation position
– Always renew clip.
. Volkswagen AG
gen AG does
– Install clamp so that ends of bolts do not protrudeVobeyond
lksw
a
bot‐ not
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t to the co
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2 Exhaust gas cleaning

. Volkswagen AG
a gen AG does
⇒ “2.1 Assembly overview - particulate filter”, page
Vol 467
ksw not
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db ara
⇒ “2.2 Assembly overview - catalytic converter,
orise
four-wheel drive nte
eo
vehicles”, page 472 aut
h
ra
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⇒ “2.3 Removing and installing particulate filter”, page 474
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nl
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⇒ “2.4 Removing and installing catalytic converter, four-wheel
itte
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2.1 Assembly overview - particulate filter
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2.1.1 Assembly overview - particulate filter,
t to the co
front-wheel drive vehicles
rrectness of i
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Note
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
nf
ercia
o
G450- are renewed, carry out adaption ⇒ Vehicle diagnostic
rm
m
tester.
atio
om
n in
c
♦ After working on the exhaust system, ensure that the system

or
thi
is not under stress and that there is sufficient clearance to the
te
sd
iva
bodywork. Loosen double clamp and clamp if necessary. Align
o
r
rp
cu
silencer and exhaust pipe so that sufficient clearance is main‐
o
m
f
en
ng
tained to the bodywork and the support rings are evenly loa‐
t.
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♦ Lambda probe open ring spanner set - 3337-
2. Exhaust gas cleaning 467

1 - Holder
❑ Fastened to fuel line
2 - Bolt
❑ 8 Nm
3 - Fastener
❑ For exhaust gas pres‐
sure sensor 1 - G450-
4 - Exhaust gas pressure sen‐
sor 1 - G450-
❑ Once new part has been
fitted, carry out adapta‐
tion ⇒ Vehicle diagnos‐
tic tester.
⇒ page 450
❑ Loosen and fasten with
hose clip pliers - VAS
6362-
6 - Lambda probe - G39-
❑ 50 Nm
❑ Grease only thread. The
high-temperature paste
⇒ Electronic parts cata‐
logue (ETKA) must not
get into the slots on the
probe body.
sender 2 - G448-
❑ Only in 62 and 75 kW
engines
AG. Volkswagen AG d
❑ Grease thread of sender agen oes
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using high-temperature ed by
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ara
paste ⇒ Electronic Parts Catalogue (ETKA) . horis nte
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ut
❑ Sender must not be bent when removing and installing.
ss a ra
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❑ Sender must not contact any other component on installation. ce
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un
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an
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❑ 45 Nm
itte
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8 - particulate filter ility
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• Assembly sequence must be adhered to during installation to ensure stress-free installation.

h re
ole,
spec
♦ Nut ⇒ Item 22 (page 469) of support ⇒ Item 28 (page 469) must be loose.
t to the co
♦ Only screw in bolt ⇒ Item 23 (page 469) loosely.

♦ Position particulate filter with new gasket ⇒ Item 9 (page 468) and new screw-type clip
⇒ Item 10 (page 469) .
rrectne
♦ Tighten screw-type clip ⇒ Item 10 (page 469) .

ss
♦ Tighten nut ⇒ Item 14 (page 469) on rear torque reaction support ⇒ Item 13 (page 469) .
o
cial p
f inform
♦ Insert and tighten bolt ⇒ Item 23 (page 469) .

mer
atio
♦ Tighten nut ⇒ Item 22 (page 469) of support ⇒ Item 28 (page 469) .

om
n
c

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9 - Seal
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468
agen
Prote AG.
Rep. gr.26 - Exhaust system
❑ 8 Nm
❑ 45 Nm
12 - particulate filter
13 - Rear torque reaction support
14 - Nut
❑ 40 Nm
15 - Union nut
❑ 45 Nm
16 - Control cable
17 - Bolt
❑ 9 Nm
18 - Vibration damper
19 - Bolt
❑ 20 Nm
20 - Clip
❑ For wiring harness of exhaust gas temperature sender 3 - G495- .
21 - Double stud
22 - Nut AG. Volkswagen AG d
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❑ 40 Nm by
Vol not
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23 - Bolt hor eo
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❑ 40 Nm ss c
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24 - Control cable pt
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25 - Bolt
rm
ab
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ility
❑ 4.5 Nm
ot
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26 - Holder
hole
spec
❑ For control lines

es, in part or in w
t to the co
27 - Bolt
❑ 8 Nm
rrectness of i
28 - Support
l purpos
29 - Holder
❑ Fastened to rear left of cylinder head
nform
ercia
30 - Bolt
m
❑ 8 Nm
com
tion in
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Prote AG.

2.1.2 Assembly overview - particulate filter,

four-wheel drive vehicles
Note
♦ If the particulate filter or the exhaust gas pressure sensor 1 -

G450- are renewed, carry out adaption ⇒ Vehicle diagnostic
tester.
tained to the bodywork and the support rings are evenly loa‐ agen
AG. Volkswagen AG d
ded. Volksw
oes
not
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db ran
♦ Renew self-locking nuts. rise tee
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an
♦ Lambda probe open ring spanner set - 3337-
d
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t to the co
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f inform
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1 - Connector
❑ Secured to bracket
sender 4 - G648-
❑ Grease thread of sender n AG. Volkswagen AG do
wage
using high-temperature olks es n
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paste ⇒ Electronic d b ua
ran
ir se
Parts Catalogue (ET‐ tho tee
or
KA) . ss
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❑ 45 Nm
ce
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un
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pe
ility
❑ Grease thread of sender
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KA) .
t to the co
❑ 45 Nm
4 - Double clamp
rrectness of i
l purpos

tion ⇒ page 466 .
nform
ercia
❑ 31 Nm
m
a
com
t
5 - Mounting
ion in
r
te o
thi
s
iva
do
6 - Bolt
r
rp
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❑ 23 Nm
en
ng
t.
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7 - Union nut
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8 - Control cable Prote AG.
9 - Control cable
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 4.5 Nm
12 - Bolt
❑ 8 Nm
13 - Exhaust gas pressure sensor 1 - G450-
❑ Once new part has been fitted, carry out adaptation ⇒ Vehicle diagnostic tester.
14 - Bolt
❑ 9 Nm
15 - Holder
❑ Secured to front axle
16 - particulate filter
❑ Handle carefully to avoid damage.


17 - Seal
❑ 8 Nm
19 - Connector
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1 - Catalytic converter
Assembly sequence must be
adhered to during installation
to ensure stress-free installa‐
tion.
❑ Install bracket
⇒ Item 6 (page 473) 6
on bevel box
⇒ Item 5 (page 473) 5.
❑ Place catalytic convert‐
er together with seal
⇒ Item 3 (page 473) 3 gen AG
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⇒ Item 8 (page 473) 8
t to the co
only finger-tight.
❑ Tighten screw-type clip
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⇒ Item 4 (page 473) 4 to
specified torque.
s
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2 - Lambda probe - G39-

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3 - Seal Prote AG.

❑ 8 Nm
5 - Bevel box
6 - Holder
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 40 Nm
9 - Holder
10 - Bolt
❑ 40 Nm

2.3 Removing and installing particulate filter
2.3.1 Removing and installing particulate filter - vehicles with front-wheel drive

equipment required
1331-
1332-
VAS 6362-
AG. Volkswagen AG d
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WARNING
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Danger of burning.
inform
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Parts of the exhaust system may be hot.

atio
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Before removing exhaust system, let it cool down.

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– Disconnect electrical connector -arrow- on lambda probe -

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– Undo clip -1- between particulate filter and exhaust pipe with
»small« tool -2-.
– Unscrew nut -1- from particulate filter on torque reaction sup‐

port at rear -2-.

– Detach connector -arrow- of exhaust temperature sender 3 -

G495- (brown connector).
AG. Volkswagen AG d
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– Unscrew bolt -1- and nut -3- and remove support -2-.
– Press the exhaust pipe to one side when removing particulate
rrectness of i
filter.
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Installing
nf
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Caution
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Assembly sequence must be adhered to during installation to Prote AG.
ensure stress-free installation ⇒ Item 8 (page 468) 8.
Note
If a new particulate filter was installed, connect ⇒ Vehicle diag‐

nostic tester and carry out “Ash mass comparison”.
Torque settings
tank
2.3.2 Removing and installing particulate filter

- vehicles with four-wheel drive

Removing
– Open clip -1- between catalytic converter and exhaust pipe
with »small« tool -2-.
– Remove cable tie -5- with blade end from holder.

– Unscrew bolt -1- from exhaust gas pressure sensor 1 - G450-
-2-. olkswage es n
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– Remove connectors -1- and -2- of exhaust gas temperature

hole
spec
sender from holder, release and detach.

es, in part or in w
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– Release wiring harness -1- from retainer -2-.

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– Loosen nuts -1- hand
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– Remove particulate
ss filter. c
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– Use new clips and gaskets.

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2.4 Removing and installing catalytic con‐

verter, four-wheel drive vehicles

AG. Volkswagen AG d
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Removing
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WARNING
spec
t to the co
Danger of burning.
Parts of the exhaust system may be hot.
rrectne
Before removing exhaust system, let it cool down.
ss o
cial p
f
– Disconnect electrical connector -arrow- on lambda probe -
inform
G39- .
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The screw-type clip -2- is secured in the pressure
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with »small« tool -2-.
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– Undo screw -arrow-.

– Remove catalytic converter.
Installing
Torque settings
♦ ⇒ “2.2 Assembly overview - catalytic converter, four-wheel

AG. Volkswagen AG d
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⇒ “3.1 Assembly overview - exhaust gas recirculation”,
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page 482 s
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⇒ “3.2 Removing and installing exhaust gas recirculation cooler”,
an
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page 485
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⇒ “3.3 Removing and installing exhaust gas recirculation valve
ot
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N18 with exhaust gas recirculation potentiometer G212 ”,
h re
page 497
hole
spec
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⇒ “3.4 Pressure loss test for exhaust gas recirculation cooler”,
t to the co
page 497
3.1 Assembly overview - exhaust gas recir‐
rrectness of i
culation
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⇒ “3.1.1 Assembly overview - exhaust gas recirculation cooler, bi-

turbo engine ”, page 482
nform
ercia
⇒ “3.1.2 Assembly overview - exhaust gas recirculation cooler,

m
a
single turbo engine ”, page 484
com
tion in
3.1.1 Assembly overview - exhaust gas recirculation cooler, “bi-turbo engine”
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1 - Oil filters
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Adhere
• to instructions for cted agen
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installing oil filter in
⇒ Maintenance ; Booklet
19 under all circumstan‐
ces.
2 - Thread insert
❑ Not available as sepa‐
rate replacement part
3 - Left pipe
4 - Bolt
❑ 8 Nm
5 - Seal
6 - Connection
7 - Bolt
8 - Coolant hose
❑ To cooler
9 - O-ring

n AG. Volkswagen A
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11 - Coolant
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12 - Bolt
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❑ Observe general notes on the lubrication system ⇒ page 7
hole
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es, in part or in w
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14 - Seals
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15 - Bolt
nform
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❑ Tighten diagonally and alternately

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❑ 15 Nm +180°
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17 - Seals
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❑ 40 Nm
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19 - Bolt
❑ 8 Nm
21 - O-ring
22 - Right pipe
23 - O-ring
❑ Installed in intake manifold.
3. Exhaust gas recirculation 483

3.1.2 Assembly overview - exhaust gas recirculation cooler, “single turbo engine”
1 - Bolt
❑ 9 Nm
2 - Connector
❑ to exhaust gas recircu‐
lation valve - N18- with
exhaust gas recircula‐
tion potentiometer -
G212-
3 - Vacuum hose
❑ From exhaust gas recir‐
culation cooler change‐
over valve - N345- . n AG. Volkswagen AG do
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5 - Coolant hose
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❑ To cooler
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7 - Rear pipe
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8 - Nut
❑ Renew after removal rrectness of i
❑ 23 Nm
l purpos
9 - Bolt
❑ 8 Nm
nf
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10 - Left pipe
m
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atio
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11 - Coolant hose
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❑ Can only be renewed together
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❑ Check for leaks ⇒ page 497 . Prote
cted AG.
agen

3.2 Removing and installing exhaust gas re‐

circulation cooler
⇒ “3.2.1 Removing and installing exhaust gas recirculation cooler,
⇒ “3.2.2 Removing and installing exhaust gas recirculation cooler,
3.2.1 Removing and installing exhaust gas recirculation cooler, “bi-turbo engine”

equipment required
agen
1331- Volksw
oes
not
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♦ Torque wrenchor-isV.A.G
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1332- au
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VAS 6362-
♦ Small hand-held mirror
rrectness of i
♦ Flexible magnet
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a
com
tion in
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4-cylinder diesel engine (2.0 l engine, commonthor rail) - Edition 08.2016 eo
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Removing
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Note
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♦ Move lock carrier to service position. Lock carrier must then
h re
hole
be supported on body using plastic or foam rubber “spacers”
spec
to obtain necessary clearance for removal and installation.
es, in part or in w
t to the co
♦ The exhaust gas recirculation cooler is removed upwards.
Contaminated areas must be cleaned thoroughly after instal‐
ling.
rrectness of i
♦ Hose clips are only partly accessible directly and can therefore
l purpos
only be removed using hose clip pliers - VAS 6340- .

♦ A small hand-held mirror is required to unscrew and insert the
nf
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threaded connection.
rm
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♦ Electrical connector and vacuum hose can only be pulled off

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c
exhaust gas recirculation cooler when it has been removed

or
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♦ First tighten bolts for exhaust gas recirculation cooler diago‐

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en
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♦ Only screw pipe bolts hand-tight first, then tighten.
cop Vo
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♦ Renew gaskets and seals.
For purposes of clarity, illustration shows parts which are to be

removed.

1 - Connector AG. Volkswagen AG d

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❑ Can only be pulled Volkswoff not
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removed.thor eo
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spec
3 - Left pipe
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bolts hand-tight first,
and then tighten.
rrectness of i
❑ 8 Nm
l purpos
4 - Coolant connection
nf
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❑ Remove and install
or
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m
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5 - Bolt
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AG.

8 - Guide tube
❑ Unbolt and remove at intake manifold and exhaust gas recirculation cooler.
9 - Bolt
❑ A small hand-held mirror is required to unscrew and insert the bolt.
❑ 40 Nm
10 - Nut
❑ A small hand-held mirror is required to unscrew and insert the nut.
❑ 25 Nm
11 - Vacuum hose
❑ Not shown in illustration.
❑ Can only be pulled off exhaust gas recirculation cooler when exhaust gas recirculation cooler has been
removed from engine.
12 - Vacuum hose
❑ Separate and detach at guide pipe.

– Unbolt pipes -1- and -4- from exhaust gas recirculation cooler,
cylinder head and intake manifold. Bear in mind different bolt
lengths for pipes.
– Separate vacuum hose -5- and unclip at guide pipe.
– Unscrew bolt -arrow- guide pipe on exhaust gas recirculation

cooler. agen
AG. Volkswagen AG d
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– Unscrew bolt from guide
ed
bypipe on intake manifold.
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au
th 187 . eo
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– Move lock carrier to service position ⇒ General body repairs,
ce
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un
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exterior; Rep. gr. 50 ; Lock carrier; Moving to service position .
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– Detach connectors -1- and -2- at lower right of body in

m
-direction of arrow-.
a
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tion in
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– Insert suitable “spacers” -arrow- on left and right between lock

carrier -1- and body -2-.

– Open clips -arrows- and remove coolant hoses -1- and -2-.

V178- -1-.
Coolant hoses and connectors remain attached.
– Open clip -arrow- and remove coolant hose -2-.

– Unscrew bolts -1- on left and right from exhaust gas recircu‐
lation cooler.
AG. Volkswagen AG d
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n
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-3-.
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Note
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A small hand-held mirror is required to unscrew and insert the

bolt.
nform
mercia
at
om
ion
c
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or
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ate
do
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– Unscrew bolt -arrow 1- on right from exhaust gas recirculation

p
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or
cooler.
f
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op
– Pull off vacuum hose -arrow 2-.
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by c lksw
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Prote AG.
– Before removing exhaust gas recirculation cooler, release

electrical connector -arrow- and pull off.
– Guide exhaust gas recirculation cooler through between in‐

take manifold -1-, transport eyelet -2- and lock carrier -3-.

– Then guide exhaust gas recirculation cooler through between

engine, air ducting -arrow 1- and fan -arrow 2-.
AG. Volkswagen AG d
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– Before bolting exhaust gas recirculation cooler on, connect
erm
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– Renew gaskets and seals.
h re
hole
spec
es, in part or in w
t to the co
– Screw in bolts hand-tight in sequence -1 to 4-.
rrectness of i
– Tighten bolts in the sequence -1 … 4-.
l purpos
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at
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ion
c
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ate
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n AG hand-tight . Volkswage
– Only screw bolt -arrow- for guide
ksw
agepipe intooeexhaust
n AG d
sn
l
gas recirculation cooler.byScrew
Vo second bolt in at intake omani‐
t gu
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fold. Then tighten both
rised
bolts. nte
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Note
le
un
pt
an
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To avoid tension or warping, screw in all bolts hand-tight first, and
erm
ab
then tighten.
ility
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spec
t to the co
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cial p
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mer
atio
– Insert right pipe -1- together with rear bolt -arrow 2-.
om
n
c
i
or
n
– Insert left pipe -4- together with new gasket and left bolt
thi
e
-arrow 3-.
t
sd
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Torque settings t. Cop py
rig
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♦ ⇒ “3.1.1 Assembly overview - exhaust gas recirculation cooler, yri
p by
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♦ Lock carrier; Assembly overview - lock carrier ⇒ General body
repairs, exterior; Rep. gr. 50 ; Lock carrier; Assembly overview
- lock carrier
3.2.2 Removing and installing exhaust gas recirculation cooler, “single turbo en‐
gine”


equipment required
3094-
1331-
VAS 6362-
AG. Volkswagen AG d
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nform
mercia
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com
tion in
r
te o
thi
s
iva
do
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cum
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Cop py
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by
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Removing
Volkswa AG. gen AG
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♦ The exhaust gas recirculation cooler
s is removed upwards.
s c
ce
le
Contaminated areas must be cleaned thoroughly after instal‐
un
pt
ling.
an
d
itte
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erm
ab
♦ Hose clips are only partly accessible directly and can therefore
ility
ot p
only be removed using hose clip pliers - VAS 6340- .
wit
is n
h re
♦ Electrical connector and vacuum hose can only be pulled off
ole,
spec
exhaust gas recirculation cooler when it has been removed
from engine.
t to the co
♦ To avoid tension or warping, screw in all bolts hand-tight first,
and then tighten.
rrectne
♦ First, align the exhaust gas recirculation cooler and the con‐
necting pipes to each other and fit the bolts by hand. Then,
s
tighten the bolts of the exhaust gas recirculation cooler and
s o
cial p
f
then tighten the bolts for the connecting pipes.
inform
mer
atio
m

o
n
c
i
or
n thi
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fo
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– Clamp off coolant hose -2- with hose clip up to 25 mm - 3094- .

– Remove clip -1- and detach coolant hose -2-.
lkswage es n
o ot g
yV
– Clamp offiscoolant
ed
b hose -2- with hose clip up to 25 ua
rmm
an - 3094- .
or tee
h
– Removeau clip -3- and detach coolant hose -2-.
t or
ac
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nl
pt
du
an
Note
itte
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ility
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Take note of the different bolt lengths for the connecting pipes
wit
and the exhaust gas recirculation cooler.

, is n
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hole
spec
– Screw bolts -1- out of connecting pipe -4-.

es, in part or in w
t to the co
rrectness of i
– Pull hose -1- off vacuum unit.

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew bolts -3- from exhaust gas recirculation cooler -2-.
Note
The bolt 1 at the bottom is difficult to reach. Use a mirror for re‐
moving and fitting.
– Unscrew bolts -1- from exhaust gas recirculation cooler -2-.

– Remove exhaust gas recirculation cooler -2- upwards towards
right.
Installing
AG. Volkswagen AG d
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Note olksw not
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♦ To avoid tension or warping, screw inauall
th bolts hand-tight first, eo
ra
and then tighten. ss c
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nl
pt
♦ First, align the exhaust gas recirculation cooler and the con‐
du
an
itte
necting pipes to each other and fit the bolts by hand. Then,
y li
erm
ab
tighten the bolts of the exhaust gas recirculation cooler and

ility
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then tighten the bolts for the connecting pipes.

wit
, is n
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hole
spec

es, in part or in w
t to the co

rrectness of i
– Checking coolant level and replenishing coolant ⇒ page 187 .

Torque settings
l purpos

nf
ercia

orm
m
atio

om
n in
c

or
thi
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tank
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t.
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Cop py
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rig ht
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Prote AG.

3.3 Removing and installing exhaust gas re‐

circulation valve - N18- with exhaust gas
recirculation potentiometer - G212-
Removing
– Remove exhaust gas recirculation cooler ⇒ page 485 .
AG. Volkswagen AG d
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olksw not
byV gu
ara
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is n
– Unscrew bolts -A-thand
or remove exhaust gas recirculation valve tee o
- N18- -1- from sexhaust gas recirculation cooler -2-.
au ra
c
s
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e
Installing
nl
pt
du
an
itte

y li
erm
ab
ility
– Mount exhaust gas recycling valve - N18- on exhaust gas re‐

ot p
wit
circulation cooler.
, is n
h re
hole

spec
es, in part or in w
Torque settings
t to the co

rrectness of i
♦ ⇒ “3.1 Assembly overview - radiator, radiator fan”, page 238

l purpos

nform
ercia

tank
m
at
om
ion
c
in t
or
3.4 Pressure loss test for exhaust gas recirculation cooler

his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Prote AG.


equipment required
- VAS 6208-
AG. Volkswagen AG d
agen
♦ Cooling system tester - Volksw
oes
not
gu
V.A.G 1274 B- ed by ara
nte
ris
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♦ Adapter for cooling system aut
h
ra
tester - V.A.G 1274/8- ss c
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nl
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an
itte
3094-
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nform
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at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
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Prote AG.
Without illustration:
♦ Coolant hose - N 020 269 1- (length as required)

♦ Hose clip
The following instructions apply for checking the exhaust gas re‐
circulation cooler on single-turbo engines while installed.
WARNING


Note
♦ In the following figure the coolant circuit is shown schematically. The green line shows the additional coolant
hose which must be installed.
♦ The illustrations in the test instructions are only examples and are only for orientation. Variations in illustra‐
tions may occur depending on the type and equipment version of the vehicle.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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pyri by
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Prote AG.

At five locations on the coolant system the coolant hoses are to

be clamped using hose clamps up to 25 mm - 3094- .
– Clamp off breather lines -1 and 2- on coolant expansion tank
using hose clamps up to 25 mm - 3094- .
– Clamp off and detach coolant hose -1- at cooler for exhaust
gas recirculation with hose clamps up to 25 mm - 3094- .
– Clamp off coolant hose -1- at cooler for exhaust gas recircu‐
lation with hose clamps up to 25 mm - 3094- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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nl
pt
du
an
itte
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ab
ility
ot p
wit
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– Clamp off coolant hoses on coolant expansion tank using hose

h re
hole
clamps up to 25 mm - 3094- .
spec
es, in part or in w
– Then extract coolant from coolant expansion tank.

t to the co
– Disconnect coolant hose from coolant expansion tank.

rrectness of i
– Install coolant hose - N 020 269 1- between expansion tank

connection and exhaust gas recirculation connection and se‐
l purpos
cure using hose clips .

nf
ercia
Note
rm
m
atio
om
Check hose clips for firm seating.

n in
or c
thi
te
sd
iva
– Fill expansion tank with coolant up to min. mark.

o
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rp
cu
o
m
f
– Create a pressure of 1.5 bar using cooling system tester -

en
ng
t.
yi Co
V.A.G 1274 B- and adapter for cooling system tester - V.A.G Cop py
1274/8- . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Check hose connections for leaks.

• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
• If When the pressure drops by more than 0.2 bar, build-up
pressure again to 1.5 bar, and repeat the test again.
Note
♦ If the exhaust gas recirculation cooler leaks, renew exhaust

gas recirculation cooler.
♦ The channels to the valves must free of coolant remnants.
– Bleed the coolant system after assembly work ⇒ page 187 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
t. rig
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Prote AG.

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Checking glow plug system”, page 502
⇒ “1.2 Removing and installing glow plug”, page 502
⇒ “1.3 Checking glow plug”, page 505
⇒ “1.4 Optical characteristics of glow plugs”, page 506
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
506
⇒ “1.6 Removing and installing Hall sender G40 ”, page 508
1.1 Checking glow plug system

Removing
– Remove electronics box on left in engine compartment ⇒
Electrical system; Rep. gr. 97 ; Relay carrier, fuse carrier,
electronics boxes; Removing and installing electronics box .
The automatic glow period control unit - J179- is located in the
relay and fuse holder in the E box.
1- Automatic glow period control unit - J179-
The glow plug system is controlled by means of an automatic glow
period control unit - J179- The automatic glow period control unit
- J179- is capable of self-diagnosis.
A fault entry is stored in the engine control unit if a fault occurs in
the glow plug system.
The procedure for checking the glow plug system is described in
Guided fault finding. wage
e ks s no
Vol t gu
For faster starting, the vehicle is equipped with electronically
ed
by con‐ ara
trolled glow plugs and a separate glow period control
ho
ris unit. nte
eo
t
au ra
Each glow plug is activated and diagnosed sindividually.
s c
ce
le
un
pt
Torque settings
an
d
itte
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♦ Relay carrier, fuse carrier, electronics boxes; ⇒ Electrical sys‐

erm
ab
ility
tem; Rep. gr. 97 ; Relay carrier, fuse carrier, electronics

ot p
wit
boxes; Removing and installing relay and fuse carrier behind

is n
h re
dash panel on driver side

ole,
spec
1.2 Removing and installing glow plug

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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t.
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Cop py
t. rig
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Prote AG.
502 Rep. gr.28 - Glow plug system


equipment required
♦ T-bar and socket, 10 mm -
3220-
♦ Pliers - 3314-
1410-
AG. Volkswagen AG d
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olksw not
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ara
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aut ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
Removing
om
ion
c
in t
– Switch off ignition.

or
his
ate
do
priv
Caution
um
for
en
ng
t.
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op
Make sure that no wiring connections are damaged when dis‐ C py
ht. rig
connecting the connectors. Otherwise the whole wiring har‐ rig ht
py by
ness will need to be renewed. Do not compress the pliers -
co Vo
by lksw
cted
3314- to firmly to separate the connectors, otherwise the
agen
Prote AG.
support sleeve may be damaged.
1. Glow plug system 503

– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Carefully pull connectors off glow pin plugs in
es, in part or in w
t to the co
-direction of arrow-.
rrectness of i
Note
l purpos
Detach all the necessary electrical connectors to ensure that the

wiring harness is not damaged.
nform
ercia
– Clean glow pin plug opening in cylinder head. It must be en‐

m
a
com
ti
sured that no dirt falls into the cylinder when this is being done.
on in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
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♦ Cleaning procedure:
Co
Cop py
ht. rig
♦ Use a vacuum cleaner to remove coarse dirt. rig ht
py by
co Vo
by lksw
♦ Spray brake cleaner or suitable cleaning agent into glow pin cted agen
Prote AG.
plug opening, let it work in briefly, and blow out with com‐
pressed air.
♦ Then use an oil-soaked cloth to clean the glow pin plug open‐
ing.
– To loosen glow plugs, use special tool U/J extension and

10 mm socket - 3220-
Installing
– Make sure that glow plug connectors are firmly seated.

– Delete engine control unit event memory.
Torque setting
Glow plug 17 Nm

1.3 Checking glow plug
Note
Observe optical characteristics of ceramic glow plugs

⇒ page 506 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Adapter set - V.A.G 1594C-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
Test sequence
or
his
ate
do
riv
• Glow plugs removed

p
cum
for
– Connect wire of hand-held multimeter - V.A.G 1526D- to glow

en
ng
t.
yi
plug 1 - V.A.G 1594C- using auxiliary clips from auxiliary
Co
Cop py
measuring set - Q10- .
t. rig
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pyri by
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– Apply test probe of hand-held multimeter - V.A.G 1526D- to
c by lksw
cted agen
glow plug 1 - Q10- “earth” and test resistance.
Prote AG.
A glow plug with a resistance up to 1 ohm is OK.

– Test glow plug 2 - Q11- , glow plug 3 - Q12- and glow plug 4
- Q13- in succession.
If the specified value is not reached, the engine glow plugs - Q6-
must be renewed.
Testing glow plugs (in situ)
– Connect ⇒ Vehicle diagnostic tester and select test program.

1.4 Optical characteristics of glow plugs

Optical characteristics of glow plugs
A - Ceramic glow plug, colour-coded white -arrow-.
B - Metal glow plug, colour-coded green or red/black -arrow-.
1.5 Removing and installing . Volkengine

swagen AG speed
gen AG
sender - G28- swa does
olk not
V gu
by d ara
se nte
tho
ri equipment required e or
au ac
♦ Torque wrench s-s V.A.G 1410-
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Socket, 4 mm - T10370-

Removing . Volkswagen AG
gen AG does
swa
– If fitted, remove noise insulation ⇒ General y Volk body repairs, ex‐ not
gu
terior; Rep. gr. 66 ; Noise insulation; risedRemoving
b
and installing ara
nte
noise insulation . ut
ho eo
ra
s a c
– Pull connector -2- off engine speed sender - G28- below oil
s
ce
le
filter holder -1-.
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
To release electrical connector without assembly tool - T10118- ,
ole,
spec
press connector on engine speed sender - G28- in with a screw‐
driver and at the same time raise release tab with a thin wire hook.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
– Unscrew bolt -arrow- with socket AF 4 mm - T10370- and re‐

fo
en
ng
move engine speed sender - G28- .

t.
yi Co
Cop py
t.
Installing
rig
gh ht
pyri by
Vo
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by c
lksw
cted agen
Prote AG.
Torque setting
Engine speed sender - G28- 5 Nm

1.6 Removing and installing Hall sender -

G40-
Removing
– Open clips -1- and remove toothed belt guard.
– Relax poly V-belt tensioning element.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Remove lower toothed belt guard. To do so, remove bolts

spec
-arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Turn engine to TDC and lock crankshaft pulley in position with

crankshaft stop - T10050- . Fit the crankshaft stop in the teeth
from the face side of the toothed belt pulley.
• The mark -2- on the toothed pulley and the arrow -1- on the
crankshaft stop - T10050- must align -arrow-. When doing this,
the pin of the crankshaft stop must engage in the drilling of
sealing flange.

The arrow on the camshaft pulley must be at almost »12 o'clock«.

– Mark direction of rotation of toothed belt -3-.
– Undo screws -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
– Lift retaining clamp (not visible in picture) then spulled bythe delivery ara
nte
hose -1- off the charge air cooler -arrow- and hori
remove. eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolt -2- from pressure pipe -1-. rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove bolts of toothed belt pulley of high-pressure pump

-2-.
– Loosen tensioning roller nut -1-.
AG. Volkswagen AG d
agen oes
olksw not
– Turn eccentric of tensioning roller anti-clockwise
d by
V -arrow- using gu
ara
offset wrench - T10264- until tensioning oris roller can be locked
e nte
eo
with locking tool - T10265- . aut
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Now turn tensioning roller eccentric clockwise -arrow- onto
rrectness of i
stop and tighten nut -1- hand-tight.
l purpos
– Remove toothed belt from idler roller and high-pressure pump.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Screw off Hall sender - G40- -arrow-.
o Vo
by c lksw
cted agen
Prote AG.

– Remove idler roller -1-.

– Using a screwdriver, remove webs -arrows- and detach wiring
harness
– Remove cover -2- of repair aperture.
– Pull wiring harness -1- out of retainer -2- and separate.

Installing
wage es n
– Seal repair aperture in toothed belt guard with rubberVol plugs as
ks ot g
by ua
specified in ⇒ ETKA (Electronic Parts Catalogue)
ise
d . ran
tee
r
ho
aut or
ac
ss
ce
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VW-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

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VW-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

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Service

4-cylinder diesel engine (2.0 l engine, common rail)

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E80219C61

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.3 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.4 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.5 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.6 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.8 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

2.3 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

2.4 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.1 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

3.2 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

3.3 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

supplementary heater from week 45/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

2.2 Assembly overview - Continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . 224

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1.8 Removing and installing connecting pipes (bi-turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

2.8 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 361

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

1.2 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

2.2 Checking vacuum system for leaks, “bi-turbo engine” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

1.4 Optical characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

1.6 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

⇒ “1.4 Safety precautions when working on the cooling system”,

⇒ “1.5 To avoid any risk of injuries to persons and/or the destruc‐

⇒ “1.6 Safety precautions when using testers and measuring in‐

When doing any repair work, especially in the engine compart‐

When removing and installing fuel gauge sender or fuel pump

1.2 Safety precautions when working on

Please observe the following points during all installation work,

♦ Make sure there is adequate clearance from all moving or