Engine Cava Cavd Cavb Cavc Cave Ckma Ctha Cthb Cthc Cthd Cthe Ctka Cnwa Repair Manual Eng

Service
Workshop Manual
Eos 2006 ➤ , Golf 2009 ➤ ,
Golf Cabriolet 2012 ➤ ,
Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,
Passat 2011 ➤ , Passat CC 2009 ➤ ,
Passat Variant 2011 ➤ , Polo 2010 ➤ ,
Scirocco 2009 ➤ , Sharan 2011 ➤ ,
Tiguan 2008 ➤ , Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, EA 111,
turbocharger, supercharger)
Engine ID
CAV CAV CAV CAV CAV CKM CTH CTH CTH
A D B C E A A B C
CTH CTH CTK CNW
D E A A
Edition 05.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Eos 2006 ➤ , Golf 2009 ➤ , Golf Cabriolet 2012 ➤ , Golf Plus 2005 ➤ , ...
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 05.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . 8
1.2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . . . 18
1.3 Removing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Installing engine (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5 Removing engine (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.6 Installing engine (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.7 Removing engine (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.8 Installing engine (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.9 Removing engine (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.10 Installing engine (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.1 Assembly overview - assembly mountings (Touran, Golf Plus, Eos, Scirocco, Golf, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2 Assembly overview - assembly mountings (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Assembly overview - assembly mountings (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Assembly overview - assembly mountings (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Assembly overview - assembly mountings (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 67
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Assembly overview - cylinder block, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan,
Passat, Passat CC, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Removing and installing poly V-belt (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.7 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.5 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Contents i
4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2 Removing and installing valve timing housing (Touran, Tiguan) . . . . . . . . . . . . . . . . . . . . 132
3.3 Removing and installing valve timing housing (Passat CC, Passat) . . . . . . . . . . . . . . . . . . 138
4 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.1 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.3 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.4 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 159
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Assembly overview - sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.2 Schematic diagram for coolant hoses (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Schematic diagram for coolant hoses (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.4 Coolant hose schematic diagram (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.6 Draining and filling coolant (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.7 Draining and filling coolant (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.8 Draining and filling coolant (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco, Golf, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.10 Checking cooling system for leaks (Sharan, Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.11 Checking cooling system for leaks (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.1 Assembly overview - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.2 Assembly overview - thermostat (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.3 Removing and installing coolant pump (Polo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
ii Contents
2.4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.5 Removing and installing coolant circulation pump V50 (Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.6 Removing and installing coolant pump (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.7 Removing and installing coolant pump belt pulley (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . 229
2.8 Removing and installing coolant circulation pump V50 (Sharan) . . . . . . . . . . . . . . . . . . . . 233
2.9 Removing and installing coolant pump belt pulley (Passat, Passat CC) . . . . . . . . . . . . . . 235
2.10 Removing and installing coolant pump (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . 241
2.11 Removing and installing coolant circulation pump V50 (Passat, Passat CC) . . . . . . . . . . 248
2.12 Assembly overview - heater element for engine preheater Z97 (Passat, Passat CC) . . . . 250
2.13 Removing and installing heater element for engine preheater Z97 (Passat, Passat CC) . . 252
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf, Touran, Golf
Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.2 Assembly overview - parts of cooling system, body side (Tiguan) . . . . . . . . . . . . . . . . . . . . 257
3.3 Assembly overview - radiator/radiator fan (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3.4 Assembly overview - radiator/radiator fan (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.5 Assembly overview - radiator/radiator fan (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 261
3.6 Removing and installing radiator fan V7 and radiator fan 2 V177 (Eos, Golf Plus, Scirocco,
Golf, Touran, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3.7 Removing and installing radiator fan V7 and radiator fan 2 V177 (Polo) . . . . . . . . . . . . . . 263
3.8 Removing and installing radiator, radiator fan V7 and radiator fan 2 V177 (Sharan) . . . . . . 264
3.9 Removing and installing radiator (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.10 Removing and installing fan cowling (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.11 Removing and installing radiator fan V7 and radiator fan 2 V177 (Passat, Passat CC) . . 270
3.12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
........................................................................ 271
3.13 Removing and installing radiator and radiator fan V7 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 272
3.14 Removing and installing radiator with charge air cooler (Polo) . . . . . . . . . . . . . . . . . . . . . . 274
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.4 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.5 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
2.1 Assembly overview - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
2.2 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
2.3 Removing and installing supercharger (Tiguan with four-wheel drive) . . . . . . . . . . . . . . . . 306
2.4 Removing and installing drive unit seal for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.1 Assembly overview - charge air system (Eos, Golf Plus, Golf, Touran, Scirocco, Tiguan,
Sharan, Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.2 Assembly overview - charge air system (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.3 Assembly overview - charge air system (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . 321
3.4 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3.6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cabriolet, Touran) . . 326
3.7 Removing and installing charge air cooler, Sharan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.8 Removing and installing charge air cooler (Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3.9 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3.10 Removing and installing charge air cooler (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . 334
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Contents iii
1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.2 Assembly overview - air filter (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.3 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.4 Removing and installing air filter housing (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
2.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
2.2 Removing and installing regulating flap control unit J808 and throttle valve module J338
........................................................................ 348
2.3 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3.3 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.1 Checking fuel pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.2 Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
(Polo, left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.3 Assembly overview - actuator for structure-borne sound R214 and control unit for structure-
borne sound J869 (Polo, right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
5 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
5.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
5.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
6 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
6.1 Removing and installing engine control unit J623 (Golf Plus, Touran) . . . . . . . . . . . . . . . . 372
6.2 Removing and installing engine control unit J623 with protective housing (Golf Plus,
Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6.3 Removing and installing engine control unit J623 (Eos) . . . . . . . . . . . . . . . . . . . . . . . . . . 376
6.4 Removing and installing engine control unit J623 with protective housing (Eos► 10.2008)
........................................................................ 377
6.5 Removing and installing engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . 379
6.6 Removing and installing engine control unit J623 with protective housing (Tiguan) . . . . . . 380
6.7 Removing and installing engine control unit J623 (Scirocco) . . . . . . . . . . . . . . . . . . . . . . . . 382
6.8 Removing and installing engine control unit J623 with protective housing (Scirocco►
09.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
6.9 Removing and installing engine control unit J623 (Golf, Golf Cabriolet) . . . . . . . . . . . . . . 385
6.10 Removing and installing engine control unit J623 (Passat, Passat CC) . . . . . . . . . . . . . . 386
6.11 Removing and installing engine control unit J623 with protective housing (Golf, Eos
11.2008►, Scirocco 10.2008►, Passat, Passat CC, Golf Cabriolet) . . . . . . . . . . . . . . . . . . 387
6.12 Removing and installing engine control unit J623 (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . 390
6.13 Removing and installing engine control unit J623 with protective housing (Polo) . . . . . . . . 391
6.14 Removing and installing engine control unit J623 (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . 392
6.15 Removing and installing engine control unit J623 with protective housing (Sharan) . . . . . . 393
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet) . . . . 396
1.2 Assembly overview - silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
1.3 Assembly overview - silencers (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
1.4 Assembly overview - silencers (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
1.5 Assembly overview - silencer (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
1.6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive) . . . . . . . . . . . . 401
1.7 Removing and installing front exhaust pipe (Golf Plus, Eos, Scirocco, Golf, Tiguan, Touran,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
1.8 Removing and installing front exhaust pipe (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
1.9 Removing and installing (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
iv Contents
1.10 Separating exhaust pipes, silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

1.11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
........................................................................ 407
1.12 Separating exhaust pipes, silencers (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
1.13 Separating exhaust pipes, silencers (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
1.14 Separating exhaust pipes/silencers (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 411
1.15 Aligning exhaust system free of stress (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . 413
1.16 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
2.1 Assembly overview - exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan,
Golf Cabriolet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
2.2 Assembly overview - exhaust gas treatment (Tiguan with four-wheel drive) . . . . . . . . . . . . 417
2.3 Assembly overview - exhaust gas treatment (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
2.4 Assembly overview - exhaust gas treatment (Sharan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
2.5 Assembly overview - exhaust gas treatment (Passat, Passat CC) . . . . . . . . . . . . . . . . . . 421
2.6 Removing and installing catalytic converter (Polo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
2.7 Removing and installing (Passat, Passat CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 428
1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Contents v
vi Contents
00 – Technical data
1 Engine number/engine data
(VRL011812; Edition 05.2018)
– Detach hose from activated charcoal filter at hose clip
-arrow-.
Engine code and engine number can be found on the sticker

-arrow- on the control housing.
Starting with the letter “C”, new four-digit engine codes have been
introduced. The first 3 places show the mechanical design of en‐
gine and are stamped on the engine as previously. The fourth digit
denotes the performance and torque rating of the engine and de‐
pends on the engine control unit - J623- . The four-digit engine
code can be found on the type plate, the vehicle data label and
on the engine control unit.
Note
Vehicles for certain export countries have no type plate. Fitting

locations for vehicle data sticker and identification plate: ⇒ Main‐
tenance ; Booklet
Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Manufac‐
tured
Golf 05.08► 05.08► 05.08► 05.08► --- ---
Plus
2005►
Golf --- 02.09► --- --- --- ---
Plus
2009►
Eos 05.08► 05.08► 05.08► 05.08► --- ---
2006▶
Tiguan 05.08► 05.11► --- --- --- ---
2008►
Sciroc‐ --- 05.08► 05.08► 05.08► --- ---
co
2009►
Touran --- --- 11.08► 11.08► --- ---
2003►
Golf --- 07.08► 07.08► 07.08► --- ---
2009►
Golf --- 06.11► --- --- --- ---
Cabrio‐
let
2012►
Volkswagen Technical Site: https://vwts.ru 1. Engine number/engine data 1

Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Sharan 07.10► --- --- --- --- ---
2011►
Polo --- --- --- --- 05.10►
2010►
Passat --- --- --- --- --- 11.10►
2011►
Passat --- --- --- --- --- 01.11►
CC
2009►
Exhaust EU5 EU5 EU5 EU5 EU5 EU5
emission
standard
Dis‐ cm3 1390 1390 1390 1390 1390 1390
plac
eme
nt
Pow kW at 110/5800 118/5800 103/5600 125/6000 132/6200 118/5800
er rpm
Tor‐ Nm at 240/1500 to 240/1500 to 220/1250 to 240/1500 to 250/2000-4 240/1750 to 4000
que rpm 4000 4000 4000 4500 500
Bor ∅ mm 76.5 76.5 76.5 76.5 76.5 76.5
e
Stro mm 75.6 75.6 75.6 75.6 75.6 75.6
ke
Compres‐ 10 10 10 10 10 10
sion ratio
RO min. 95 unleaded 95 unleaded 95 unleaded 95 unlea‐ 98 unlea‐
Bioethanol E85
N ded ded
or super unlea‐ 1)
ded RON 95
Injection, ig‐ Motronic MED Motronic MED Motronic Motronic Motronic Motronic MED
nition 17 17 MED 17 MED 17 MED 17 17.5.1
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Type of mix‐ Homogene‐ Homogene‐ Homogene‐ Homogene‐ Homogene‐ Homogeneous
ture forma‐ ous ous ous ous ous
tion
Charging Turbocharger Turbocharger Turbocharg‐ Turbo‐ Turbo‐ Turbocharger
and mechani‐ and mechani‐ er and me‐ charger and charger and and mechanical
cal super‐ cal super‐ chanical su‐ mechanical mechanical supercharger
charger charger percharger super‐ super‐
charger charger
1)E85 means that the fuel contains up to 85% bioethanol. Any
mixture ratio below 85% is permissible.
Engine CTHA CTHB CTHC CTHD, CNWA CTHE

code CTKA
Manu‐
fac‐
tured
Gol --- --- --- 05.12► 10.10► ---
f
Plu
s
200
9►
Eos --- --- --- 05.12► --- ---
200
6▶
2 Rep. gr.00 - Technical data


code CTKA
Ti‐ 05.12► --- --- 05.12► --- ---
gua
n
200
8►
Scir --- --- --- 05.12► --- ---
oc‐
co
200
9►
Tou --- 05.12► 05.12► --- --- ---
ran
200
3►
Gol --- --- --- 05.12► --- ---
f
200
9►
Sha 05.12► --- --- --- --- ---
ran
201
1►
Pas --- --- --- 05.12► --- ---
sat
201
1►
Po‐ --- --- --- --- --- 05.12►
lo
201
0►
Ex‐ EU5 EU5 EU5 EU5 EU4 EU5
haust
emis‐
sion
stand‐
ard
Di cm3 1390 1390 1390 1390 1390 1390
s
pl
a
c
e
m
e
nt
P kW 110/58 125/60 103/56 118/58 118/58 132/62
o at 00 00 00 00 00 00
w rpm
er
T Nm 240/15 240/15 220/12 240/15 240/15 250/20
or at 00 to 00 to 50 to 00 to 00 to 00-450
q rpm 4000 4500 4000 4500 4500 0
u
e
B ∅ 76.5 76.5 76.5 76.5 76.5 76.5
or mm
e
St mm 75.6 75.6 75.6 75.6 75.6 75.6
ro
k
e
1. Engine number/engine data 3


code CTKA
Com‐ 10 10 10 10 10 10
press‐
ion ra‐
tio
R min 95 un‐ 95 un‐ 95 un‐ 95 un‐ 95 un‐ 98 un‐
O . leaded leaded leaded leaded leaded leaded
N
Injec‐ Motron‐ Mo‐ Motron‐ Motron‐ Motron‐ Mo‐
tion, ig‐
ic MED tronic ic MED ic MED ic MED tronic
nition 17 MED 17 17 17 MED
17 17
Firing 1-3-4-2 1-3-4- 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-
order 2 2
Type Homo‐ Homo‐ Homo‐ Homo‐ Homo‐ Homo‐
of mix‐ gen‐ gen‐ gen‐ gen‐ gen‐ gen‐
ture eous eous eous eous eous eous
forma‐
tion
Charg‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐
ing charger charg‐ charger charger charger charg‐
and er and and and and er and
me‐ me‐ me‐ me‐ me‐ me‐
chani‐ chani‐ chani‐ chani‐ chani‐ chani‐
cal su‐ cal su‐ cal su‐ cal su‐ cal su‐ cal su‐
per‐ per‐ per‐ per‐ per‐ per‐
charger charg‐ charger charger charger charg‐
er er
Volkswagen Technical Site: https://vwts.ru

2 Safety precautions
⇒ “2.1 Safety regulations for working on fuel supply”, page 5
⇒ “2.2 Safety precautions when working on ignition system”, page
5
⇒ “2.3 Releasing pressure in high-pressure area”, page 6
2.1 Safety regulations for working on fuel

supply
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.
When removing and installing fuel gauge sender - G- or fuel pump

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

to avoid injuries and skin contact. Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
♦ Even before work 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!
2.2 Safety precautions when working on ig‐

nition system
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
2. Safety precautions 5
If test and measuring instruments are operated from the front

passenger seat and the vehicle is involved in an accident, a per‐
son sitting in this seat may receive serious injuries when the
airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage. ⇒ page 428
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
2.3 Releasing pressure in high-pressure

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

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

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

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

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

generated ⇒ Vehicle diagnostic tester “Guided Functions”.

3 General repair instructions

⇒ “3.1 Rules for cleanliness”, page 7
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
3. General repair instructions 7

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)”, page 8
⇒ “1.2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)”, page 18
⇒ “1.3 Removing engine (Tiguan)”, page 20
⇒ “1.4 Installing engine (Tiguan)”, page 28
⇒ “1.5 Removing engine (Polo)”, page 31
⇒ “1.6 Installing engine (Polo)”, page 39
⇒ “1.7 Removing engine (Sharan)”, page 40
⇒ “1.8 Installing engine (Sharan)”, page 48
⇒ “1.9 Removing engine (Passat, Passat CC)”, page 50
⇒ “1.10 Installing engine (Passat, Passat CC)”, page 60
1.1 Removing engine (Golf Plus, Eos, Scir‐

occo, Golf, Touran, Golf Cabriolet)
Note
♦ Crankcases were installed with different size threaded holes.

♦ Check these holes before dismantling/assembling and install
the respective engine support.
♦ The engine support - T40075- can continue to be used if con‐
verted as described in the respective work sequence.
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
work sequence.
Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.
8 Rep. gr.10 - Removing and installing engine

Special tools and workshop

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

support - T40075A- (not illustrated) with adapters /4, /5, /6
♦ Torque wrench - V.A.G 1331-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-
1. Removing and installing engine 9

♦ Hose clamp pliers - VAS 6340-

♦ Stepladder - VAS 5085-
♦ Guide pins - T10093-
Note
The battery earth must be disconnected for the remaining proce‐

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

– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
– Unbolt heat shield over turbocharger -arrows-.

– Remove air filter ⇒ page 341 .
– Open and close expansion tank cap to release pressure in
cooling system.
– Drain coolant ⇒ page 184 .
Note
Pull coolant hoses off engine with hose clip pliers - VAS 6340- .
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Remove hose -2- from activated charcoal filter system sole‐

noid valve 1 - N80- to activated charcoal filter.

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 7 .
– Remove noise insulation.
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier; Service po‐
sition .
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove battery and battery tray. ⇒ Electrical system; Rep.
gr. 27 ; Removing and installing battery .
– All cable ties which were opened or cut when the engine was
removed must be replaced with new cable ties in the same
positions when engine is installed.
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
gloves to avoid injuries and skin contact. Wrap a cloth around
the connection before loosening hose connections. Then re‐
lease pressure by carefully pulling hose off connection.
– Pull vacuum and breather hoses off engine.

– Pull connectors off thermal switch and radiator fan.
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Remove engine control unit - J623- . ⇒ page 372
– Open all line guide fasteners -arrows-.

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

– Remove hoses for activated charcoal filter -arrows-.
– Pull activated charcoal filter -1- upwards out of bracket.
– Unbolt bracket -arrows-.

– Remove wiring for Lambda probe after catalytic converter -
G130- and for alternator from cable guides -arrows-.
– Pull connector off Lambda probe after catalytic converter -

G130- and remove.

– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.
– Unbolt exhaust pipe together with flexible joint -arrows-.
– Loosen securing bolts of clamp -arrows- and pull exhaust pipe

to rear.
– If fitted, unscrew bolts -arrows- and remove bracket -1-.

– Disconnect pendulum support -arrows-.

– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
– Remove strut -1-.
– Detach slave cylinder -arrows- and place to one side. Do not

open pipes.
– Remove hydraulic clutch slave cylinder ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism .
Note
Do not depress clutch pedal.
– Remove poly V-belt. ⇒ page 75

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing system; Rep. gr. 87 .
Note
The air conditioning system lines must not be opened.
– Secure air conditioner compressor to lock carrier.

– Ensure that lines are not kinked.
– Remove right drive shaft; unbolt left drive shaft at gearbox,
raise and secure ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
sition .
Work sequence with engine support - T40075-
Engine support - T40075- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

– Screw adapter T40075/4 into crankcase to stop.

– Position engine support - T40075- with adapters -/5- and -/6-
on crankcase.
– Secure engine support - T40075- hand-tight to crankcase us‐

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

Work sequence with engine support - T40075A-
Engine support - T40075A- with adapters -/4-, -/5- and -/6- is re‐

– Screw adapter T40075A /4 into the crankcase to stop.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.
– Tighten all bolts on engine support - T40075A- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
– Unbolt engine side of assembly mounting from above

-arrows-.

– Unbolt gearbox side of assembly mounting from above

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

♦ When lifted out, the engine/gearbox assembly must be care‐
fully guided to prevent damage to the bodywork.
– Carefully lower engine and gearbox.

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .
1.2 Installing engine (Golf Plus, Eos, Scir‐

occo, Golf, Touran, Golf Cabriolet)
Installation is carried out in the reverse order. When installing,
note the following:
Caution

sitions.
– Check clutch release bearing for wear and renew if necessary.

– Lightly lubricate clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease for clutch plate
splines - G 000 100- .
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
– When swinging engine/gearbox assembly in, ensure that there
is clearance between drive shafts.
Align engine mountings as follows:

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

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ Ensure that edges of support arm on gearbox assembly
mounting -2- and gearbox support -1- are parallel.
– Install pendulum support.
Note
Specified torques for assembly mountings ⇒ page 64 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

shafts.
– Install air conditioning system compressor ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 .
– Install poly V-belt. ⇒ page 75
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 02S; Rep. gr. 30 ; Repairing clutch mechanism .
– Install selector mechanism ⇒ 6-speed manual gearbox 02S;
Rep. gr. 34 ; Repairing selector mechanism .
– Install noise insulation.
Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf,
Touran, Tiguan, Golf Cabriolet). ⇒ page 184
Draining and filling with coolant (Polo). ⇒ page 188
– Install air filter ⇒ page 341 .
– Install battery and battery carrier ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

– Push engine cover panel down at points -1- in direction of

-arrow- until it engages.
– Connect Vehicle diagnosis, testing and information system -
VAS 5051B- .
– Erase learnt values and adapt engine control unit to throttle
valve module ⇒ Vehicle diagnostic tester “Guided Functions”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
ded fault finding”.
– End the vehicle system test so that any entries stored in the
event memory during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.3 Removing engine (Tiguan)

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



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

ted as described in the respective work sequence.

– Drill a hole with a 13.0 mm bit.


Note


rection of -arrow-.

cooling system.
Note
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Remove hose -2- from activated charcoal filter system sole‐

noid valve 1 - N80- to activated charcoal filter.
WARNING

– Seal lines so that fuel system is not contaminated by dirt.
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
sition .
– Remove battery and battery tray. ⇒ Electrical system; Rep.
gr. 27 ; Removing and installing battery .
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover
– Remove engine control unit - J623- . ⇒ page 372



– Disconnect connector for Lambda probe after catalytic con‐
verter - G130- .
– Remove Lambda probe after catalytic converter - G130- -1-.


Vehicles with all-wheel drive
– Remove both drive shafts ⇒ Repairing drive shafts; Rep. gr.
40 ; Removing and installing drive shafts .
– Remove securing bolts -1- and -2- for exhaust pipe mounting.
– Remove exhaust pipe mounting downwards.

– Loosen securing nuts of clamping sleeve -arrows- and slide it

forwards on exhaust pipe -1-.
– Unscrew nuts -arrows- and pull exhaust pipe backwards.

– Push exhaust pipe backwards out of mounting -1-.
– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Lowering subframe .
– Remove exhaust pipe forwards.
– Remove gearbox carrier from bevel box ⇒ 6-speed manual
gearbox 0A6; Rep. gr. 34 ; Removing and installing bevel box .
Vehicles with front-wheel drive

to rear.
Continued for all vehicles


gearbox 0A6; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed

manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .
Note
– Remove poly V-belt. ⇒ page 78

Note


-/6- on crankcase.


using bolt -1-.
– Tighten all bolts on engine support - T40075A- to 20 Nm.

- V.A.G 1383 A- .

-arrows-.

-arrows-.
Note


carry out repairs.
– Unbolt gearbox.
1.4 Installing engine (Tiguan)

note the following:

Caution

sitions.

splines - G 000 100- .


♦ Ensure that edges of support arm on gearbox assembly
mounting -1- and gearbox support -2- are parallel.
– Install exhaust pipe.
Vehicles with all-wheel drive
– Install gearbox carrier for bevel box ⇒ 6-speed manual gear‐
box 0A6; Rep. gr. 34 ; Removing and installing bevel box .
Note
First tighten securing nuts hand-tight.
– Install exhaust pipe mounting and tighten securing bolts -1-

and -2- to 25 Nm.
Specified torques for exhaust pipe ⇒ page 417 .
– Install subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Removing and installing subframe .
– Install propshaft ⇒ Propshaft and rear final drive; Rep. gr. 39 ;
Removing and installing propshaft .
shafts.
– Attach selector mechanism ⇒ 6-speed manual gearbox 0A6;
Rep. gr. 34 ; Repairing selector mechanism .
– Install hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed
manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .
Note
Specified torques for engine/gearbox assembly mountings

⇒ page 65

– Install poly V-belt. ⇒ page 78
gr. 97
– Fill with coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Ti‐
guan, Golf Cabriolet). ⇒ page 184


– Connect Vehicle diagnosis, testing and information system -
VAS 5051B- .
– Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
1.5 Removing engine (Polo)
Note


equipment required
♦ Engine support - T10416- with adapters /1, /2, /3



♦ Torque wrench (40 … 200 Nm) - V.A.G. 1332-
Note


rection of -arrow-.

– Pull hose -1- off at camshaft housing.
– Open spring-type clip -2- and pull intake hose off.

– Pull intake hose out of intake connection.
– Unscrew securing bolt and pull air filter housing -4- upwards.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove noise insulation securing bolts -arrows-.

cooling system.
WARNING

– Pull coolant hoses off at heat exchanger behind intake mani‐
fold.
– Unplug connector -1-.
– Pull vacuum hose -2- off at vacuum pump for brakes - V192-
-3-.
RHD only
– Additionally pull vacuum hose off at brake servo.
– Secure vacuum hose to engine with cable tie.
– Unplug connector -1-.
– Pull coolant hoses -2- off coolant expansion tank.

– Unscrew securing bolts -3- and pull coolant reservoir upwards.
– Release coolant hoses -arrows- at gearbox side and pull them

off.
– Pull coolant hoses off at radiator and remove completely.
– Remove engine control unit ⇒ page 372 .
– Remove wiring harness from wiring guides and secure to en‐
gine with cable ties.
– Remove main fuse box in engine compartment ⇒ Electrical
system; Rep. gr. 97 ; Removing and installing main fuse box
in engine compartment .
– Secure main fuse box to side of body with cable ties.
– Remove selector lever cable ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable .

– Unscrew securing nuts on turbocharger -arrows-.
– Remove charge air hose -arrow-.

ing; Rep. gr. 87
Note

– Disconnect connector -3- for Lambda probe after catalytic
converter - G130- .
– Also disconnect all further connectors at gearbox support.

– Unscrew securing bolts -1- for charge air pipe.
– Unscrew securing bolts -4- and remove bracket -5-.
– Pull upper charge air hose off turbocharger.
– Remove charge air pipe downwards.
– Press front exhaust pipe support rings off pins.

– Loosen securing bolts of clamp -arrows- and slide to rear.

– Remove catalytic converter with front exhaust pipe down‐
wards.
– Remove poly V-belt ⇒ page 75 .
– 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.
– Remove right and left drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts; Removing and
installing drive shafts .
Caution
Bolt -1- must not be loosened.
– Remove pendulum support securing bolts -arrows-.

– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
Engine support - T10416- with adapters -/1-, -/2- and -/3- is re‐

– Screw adapter - T10416/1- to stop into crankcase.

– Position the engine support - T10416- with adapters -/2- and
-/3- on crankcase.
– Secure engine support - T10416- hand-tight to crankcase us‐
ing a bolt -1-.
– Tighten all bolts on engine support - T10416- to 20 Nm.
Note
Adjuster nut -2- sets correct angle between pin on engine support
- T10416- and engine and gearbox jack - V.A.G 1383 A- .
– Position engine and gearbox jack - V.A.G 1383 A- on engine

support - T10416- .
- V.A.G 1383 A- .
Note
To remove securing bolts use a stepladder - VAS 5085- .
– Unbolt earth wire -1-.
Caution
Nut -2- must not be loosened.
– Unscrew securing bolts -arrows- for engine mounting.

– Remove complete engine mounting.

– Unscrew securing bolts -arrows- at gearbox mounting.
Note
When lowering engine, guide it carefully to prevent damage.

carry out repairs.
– Unbolt gearbox.
1.6 Installing engine (Polo)

note the following:
Caution

♦ Route all the various lines, e.g. for fuel, coolant, refriger‐
ant, vacuum and electrical wiring, in their original posi‐
tions.



– Bolt on gearbox.
Specified torques for gearbox: ⇒ Rep. gr. 34 ; Removing and
installing gearbox
– Rock engine to align engine mountings stress-free.
Note
Specified torques for engine/gearbox assembly mountings

⇒ page 64
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.

40 ; Removing and installing subframe .
shafts .
– Install selector lever cable: ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable
– Install poly V-belt ⇒ page 75 .
– Electrical connections and routing: ⇒ Electrical system; Rep.
gr. 97 .
– Install noise insulation beneath engine.
– Fill with coolant (Polo). ⇒ page 188
– Connect ⇒ Vehicle diagnostic tester.
valve module “Guided functions”.
– Carry out vehicle system test.
1.7 Removing engine (Sharan)


equipment required

Note



– Drill hole through the material with 13.0 mm bit.


Note

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

cooling system.
Note

– Pull coolant hoses -arrows- off coolant expansion tank.
WARNING
– Disconnect the fuel supply line -1- and line from activated
charcoal filter system solenoid valve 1 - N80- -2- on the clutch.
Note
Press in securing ring to release fuel and breather lines.
– Seal lines so that no dirt is able to enter fuel system.

– Remove engine splash guard at bottom.
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery
is installed.
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Remove engine control unit - J623- ⇒ page 372 .



verter - G130- .




– Remove exhaust pipe.

Vehicles with manual gearbox:
gearbox 0BB; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed

manual gearbox 0BB; Rep. gr. 30 ; Assembly overview - hy‐
draulic system .
Caution
Do not operate clutch pedal any more.
Vehicles with dual clutch gearbox:

– Remove selector mechanism from gearbox ⇒ 6-speed dual
clutch gearbox 02E; Rep. gr. 34 .
Continued for all vehicles:
Note
– Secure AC compressor to lock carrier.

– Make sure that lines are not kinked.

– Disconnect coolant pipe -1- from the cylinder block.

shafts .

-/6- on crankcase.

using bolt -1-.

– Tighten all bolts on the engine support - T40075A- to 20 Nm.

- V.A.G 1383 A- .

-arrows-.

-arrows-.
Note


carry out repairs.
– Unbolt gearbox.
1.8 Installing engine (Sharan)

Repairing the clutch:
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox
0BB; Rep. gr. 30 .
♦ Vehicles with dual clutch gearbox ⇒ 6-speed dual clutch gear‐
box 02E; Rep. gr. 30 .
note the following:

Caution

sitions.

splines - G 000 100- .
– Fix hydraulic clutch slave cylinder hose: ⇒ 6-speed manual
gearbox 0BB; Rep. gr. 30 ; Assembly overview - hydraulic
system .
– Install gearbox selector mechanism and adjust if necessary ⇒
6-speed manual gearbox 0BB; Rep. gr. 34 .
Vehicles with dual clutch gearbox:
– Install gearbox selector lever cable and adjust if necessary ⇒
6-speed dual clutch gearbox 02E; Rep. gr. 34 .
Align the engine mountings as follows:


♦ Ensure that edges of support arm -1- and gearbox bracket
-2- are parallel.
– Install the exhaust pipe.
shafts.
– Install the pendulum support.
Note

gr. 97
– Add coolant ⇒ page 192 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.

– Connect vehicle diagnosis and service information system -
VAS 5051B- .
– Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
– Finish vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.
which have occurred.
1.9 Removing engine (Passat, Passat CC)


equipment required

Note



– Drill hole through the material with 13.0 mm bit.


Caution
Proceed very carefully to prevent unnecessary dismantling or

further damage.
Note
♦ The battery earth must be disconnected for the remaining pro‐

cedure. Check whether a coded radio is fitted. Then obtain
anti-theft coding first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
is installed.
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 hoses, pipes and cables so that they are in their
original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front, noise insulation .
rection of -arrow-.


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

Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

cooling system.
– Release retaining clip -arrow-.

– Pull off coolant hose -1- from radiator.
Note
– Pull coolant hoses -arrows- off coolant expansion tank.
WARNING
Note
– Release connector -2- and pull off.

– Unclip line from bracket -1-.
– Remove bracket -1- with fuel quality sender - G446- , un‐
screwing bolts -arrows- to do so.
– Release fuel lines on fuel quality sender - G446- and pull off
– Remove engine control unit - J623- ⇒ page 372 .


necting and reconnecting battery
is installed.
Vehicles with push-fit charge air hoses
– Release securing clip on right of charge air cooler in direction

of -arrow- and pull off hose -arrow-.
– Release and pull off charge air hose in same way on left-hand
side.
Vehicles with screw-type hose clips on charge air hoses

– Loosen screw-type hose clip -arrow-.
– Pull off charge air hose -1- on left of charge air cooler -2-.
– Loosen screw-type hose clip on right-hand side as well and
pull off charge air hose.


verter - G130- .

Caution
Risk of damage to flexible joint.

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

– Unclip bracket -2- on subframe for electric wire to oil level and
oil temperature sender - G266- .
Vehicles with engine preheating element - Z97-

– Unclip locking mechanism -arrow-.
– Pull off wiring -1- on engine preheating element - Z97- -2-.

– Unclip wire -1- to engine preheater heater element - Z97- on

charge air pipe -2- -arrow-.

– Unscrew nuts -arrows A- on exhaust pipe -1-.

– Push front exhaust pipe -2- backwards out of mounting
-arrows B -.
– Remove front exhaust pipe forwards.
Vehicles with manual gearbox
– Unbolt selector mechanism from gearbox: ⇒ Rep. gr. 34 ;
Repairing selector mechanism
– Remove slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ;
Repairing clutch mechanism
Note

shafts .
Vehicles with automatic gearbox
– Remove selector lever cable ⇒ Rep. gr. 34 ; Removing and
installing selector lever cable .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts .

Vehicles with auxiliary heater

– Disconnect coolant pipes -1- from cylinder block and remove.

– Undo and remove bolts -arrows- of cowling.
– Remove cowling downwards.
Vehicles with air conditioning system
ing; Rep. gr. 87
Note

– Make sure lines are not kinked.
– Unscrew bolts -arrows-.

– Remove bracket -1-.


-/6- on crankcase.

using bolt -1-.
– Tighten all bolts on the engine support - T40075A- to 20 Nm.

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

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

-arrows-.

Assembly mountings on the gearbox side with 2 bolts at gearbox

-arrows-.
Assembly mountings on the gearbox side with 3 bolts at gearbox

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

guided to prevent damage to the bodywork.

carry out repairs.
– Unbolt gearbox.
1.10 Installing engine (Passat, Passat CC)

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

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

– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.


– Bolt on gearbox.
Align engine mountings as follows

Align gearbox mountings as follows in the case of a gearbox

brackets with 2 bolts on the gearbox
-1- are parallel.

Align gearbox mounting as follows if gearbox bracket is secured

to gearbox by three bolts.
-1- are parallel.
– Install the pendulum support.
Note

– Install slave cylinder of hydraulic clutch: ⇒ Rep. gr. 30 ; Re‐
pairing clutch mechanism .
– Mount selector mechanism: ⇒ Rep. gr. 34 ; Repairing selector
mechanism .
Vehicles with automatic gearbox
– Install selector lever cable: ⇒ Automatic gearbox 09M; Rep.
gr. 34 ; Removing and installing selector lever cable
– Install air conditioner compressor: ⇒ Heating, air conditioning
system; Rep. gr. 87 .
shafts .
– Install catalytic converter and exhaust pipe.
Specified torques for exhaust system ⇒ page 421
Caution
The screw-type clips on the charge air pipes must be tightened

to 5.5 Nm. If the torque is too low or too high, the charge air
hose may slip off the charge air pipe during vehicle operation.
Note
Note installation of charge air hoses.

– If oil seal is renewed, place seal in groove of charge air hose.

Ensure that seal is correctly seated around groove and is not
twisted.
– Coat sealing surface and oil seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling as far as stop.
– Bring retaining clip to locking position -2- and then press
charge air hose again.
– Pull on hose to ensure that plug-in connector is properly seat‐
ed and engaged.
– Install noise insulation or skid plate ⇒ General body repairs,
exterior; Rep. gr. 50 ; Removing and installing noise insulation
or skid plate .
gr. 97 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.

– Connect vehicle diagnostic tester .
valve module ⇒ Vehicle diagnostic tester “Guided functions”.
– Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐
– Finish vehicle system test so that any event entries stored
during assembly can be cleared automatically.
Note safety precautions applicable to a road test.
which have occurred.

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings (Touran, Golf
Plus, Eos, Scirocco, Golf, Golf Cabriolet)”, page 64
⇒ “2.2 Assembly overview - assembly mountings (Tiguan)”, page
65
⇒ “2.3 Assembly overview - assembly mountings (Polo)”,
page 66
⇒ “2.4 Assembly overview - assembly mountings (Sharan)”, page
67
⇒ “2.5 Assembly overview - assembly mountings (Passat, Passat
CC)”, page 67
2.1 Assembly overview - assembly mount‐

ings (Touran, Golf Plus, Eos, Scirocco,
Golf, Golf Cabriolet)
Note
The securing bolts for the assembly mountings are stretch bolts
and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

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

1) Renew

Pendulum support
A 1) = property class 8.8 = 40 Nm + 90° (1/4 turn) further
A 1) = property class 10.9 = 50 Nm + 90° (1/4 turn) further
B 1) = 100 Nm + 90° (1/4 turn) further
1) Renew

ings (Tiguan)
Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

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

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

1) Renew
2. Assembly mountings 65

ings (Polo)
Note

Caution
Nut -arrow- must not be loosened.
Engine mounting
A = 20 Nm + turn 90° further
B = 30 Nm + turn 90° further
Gearbox mounting
C = 50 Nm + turn 90° further
Caution
Bolt -arrow- must not be loosened.
Pendulum support


ings (Sharan)
Note

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

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

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

1) Renew

ings (Passat, Passat CC)
Note

2. Assembly mountings 67
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
Assembly mountings with 2 bolts at gearbox

A 1) = 40 Nm + 90° further
B 1) = 60 Nm + 90° further
1) Renew
Assembly mountings with 3 bolts on gearbox

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

1) Renew
Pendulum support
C Bolt M10 1) = 100 Nm + 90° (1/4 turn) further

1) Renew

13 – Crankshaft group
1 Cylinder block (pulley end)
Note
♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
♦ Oil all bearing and running surfaces before assembly.
Note
Secure engine on engine and gearbox support - VAS 6095- to

carry out repairs.
⇒ “1.1 Assembly overview - poly V-belt drive”, page 71

⇒ “1.2 Assembly overview - cylinder block, belt pulley end”, page
73
⇒ “1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scir‐
occo, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cab‐
riolet)”, page 75
⇒ “1.4 Removing and installing poly V-belt (Tiguan)”, page 78
⇒ “1.5 Removing and installing bracket for ancillaries”,
page 80
⇒ “1.6 Renewing crankshaft oil seal - pulley end”, page 81
⇒ “1.7 Removing and installing crankshaft pulley”, page 83
Part I ⇒ page 71
Part II ⇒ page 73
1. Cylinder block (pulley end) 69

70 Rep. gr.13 - Crankshaft group

1.1 Assembly overview - poly V-belt drive
1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ To loosen and tighten
securing bolt, counter‐
hold supercharger shaft
with 16 mm spanner.
❑ Renew
2 - Belt pulley
❑ For supercharger
3 - 23 Nm
4 - Tensioning element
❑ For supercharger poly
V-belt
❑ Relieve tension using
16 mm spanner.
❑ Lock with locking pin -
T10060 A- .
5 - 8 Nm
6 - Coolant pump with magnet‐
ic clutch for supercharger -
N421-
❑ Removing and installing
(Golf, Golf Plus, Eos,
Polo, Tiguan, Touran,
Scirocco, Golf Cabrio‐
let) ⇒ page 213
(Sharan) ⇒ page 224
(Passat, Passat CC)
⇒ page 241
coolant pump belt pulley
(Golf, Golf Plus, Eos, Polo, Tiguan, Touran, Scirocco, Golf Cabriolet) ⇒ page 217
❑ Removing and installing coolant pump belt pulley (Sharan) ⇒ page 229
❑ Removing and installing coolant pump belt pulley (Passat, Passat CC) ⇒ page 235
7 - 23 Nm
❑ For poly V-belt.
❑ Release tension using open-end spanner 16 mm - T10447-
❑ Lock with locking pin - T10060 A- .
Note
♦ Vehicles with a manual gearbox:

idler roller installed instead of
tensioning element.
♦ Specified torque for securing
bolt: 40 Nm.

9 - 23 Nm
10 - Alternator
11 - Belt pulley
❑ For crankshaft
❑ With diamond coated washer
❑ Observe note on diamond coated washers ⇒ page 82 .
❑ Contact surfaces must be free of oil and grease.
12 - Securing bolt
❑ Removing and installing crankshaft pulley ⇒ page 83
❑ Renew
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure belt pulley against turning with counterhold - 3415- .
❑ Turning further can be done in several stages.
❑ The turning further angle can be measured with a commercial protractor.
13 - 40 Nm + 1/4 turn (90°) further
❑ Removing and installing with vehicle raised
❑ Renew
14 - Air conditioner compressor
15 - 23 Nm
❑ For poly V-belt.
❑ Relieve tension with spanner.
❑ Lock with 4 mm Allen key.
17 - Poly V-belt
❑ Mark direction of rotation before removing.
Caution
When installing poly V-
belt, observe direction of
rotation and make sure it
is properly seated on pul‐
leys and tensioning ele‐
ments.
❑ Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Sharan, Passat, Passat CC,
Golf Cabriolet) ⇒ page 75
❑ Removing and installing poly V-belt (Tiguan) ⇒ page 78
18 - Poly V-belt
❑ Mark direction of rotation before removing.
Caution
ments.

1.2 Assembly overview - cylinder block, belt pulley end
1 - Cylinder head with cam‐

shaft housing
⇒ page 116
❑ Do not rework sealing
surface.
❑ With integrated cam‐
shaft bearings.
❑ Remove sealant resi‐
due.
❑ When installing, insert
vertically from above so
that dowel pins fit into
holes in cylinder head
2 - Cylinder block
❑ Dismantling and assem‐
bling cylinder block
⇒ page 87 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 101
3 - Ancillary bracket
❑ For tensioning element
and air conditioner com‐
pressor
⇒ page 80
4 - Cover
5 - Sprocket
❑ For oil pump drive and
timing chain.
❑ Contact surfaces must
be free of oil and grease.
6 - 20 Nm + 1/4 turn (90°) further
❑ Renew
7 - Sprocket
❑ Lock chain sprocket using counterhold - T10172- .
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - 25 Nm
10 - Locating pin for chain tensioner
❑ Specified torque: 8 Nm
11 - Chain tensioner with tensioning rail
❑ For oil pump drive.
12 - Spring
13 - Oil pan
❑ Removing and installing ⇒ page 171
❑ Clean sealing surface before fitting.

❑ Install with silicone sealant - D 176 600 A1- .
14 - 13 Nm
15 - Piston
❑ For drive chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve timing housing
❑ Additionally install with silicone adhesive sealant - D 176 501 A1- .
❑ To facilitate guidance on installation, screw two “M6x80” studs into camshaft housing and cylinder block.
❑ To guide valve timing housing, secure sump in position with two bolts.
20 - 10 Nm
21 - Belt pulley
❑ Note tightening sequence ⇒ page 83 .
22 - Securing bolt
❑ Renew
23 - Bearing bush
24 - O-ring
❑ Renew
25 - 50 Nm
26 - Seal
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ Renew
28 - 50 Nm + 1/4 turn (90°) further
❑ Renew
29 - Tensioning rail
30 - Camshaft adjuster
❑ Must not be dismantled.
31 - Timing chain

32 - Sprocket
❑ For exhaust camshaft
❑ Lock sprockets using counterhold -T10172- .
33 - Slide rail
❑ For timing chain
34 - Guide pin
35 - Bearing bush
1.3 Removing and installing poly V-belt

(Golf Plus, Eos, Scirocco, Golf, Touran,
Polo, Sharan, Passat, Passat CC, Golf
Cabriolet)
Special tools and workshop equipment required
♦ Locking pin - T10060 A-
♦ 16 mm open-end spanner - T10447- (not shown)

♦ 4 mm Allen key
Removing
Note
The belt drive can be fitted with a tensioning element and an idler
roller or with two tensioning elements.

– Mark direction of rotation of poly V-belt.

Polo only
– Press filler neck for windscreen washer fluid out of bracket in
-direction of arrow-.
Sharan only
– Open retaining clip of refrigerant line -arrow-.

Vehicles with two tensioning elements
– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Lock tensioning element using locking pin - T10060 A- .

– To slacken poly V-belt, swing tensioning element in direction

of -arrow- from below using 16 mm open-end spanner.
– Lock tensioning element with a 4 mm Allen key -1-.
– Remove poly V-belt -2-.
Installing
Caution
Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.
– Fit poly V-belt first over crankshaft pulley. Finally, push belt
onto tensioning roller.
Further assembly is basically a reverse of the dismantling se‐
quence.
After completing repairs:
– Start engine, and check if belt runs properly.
1.3.1 Poly V-belt routing

Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Crankshaft pulley
3 - Tensioning pulley
4 - Tensioning roller or idler roller
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt

1.4 Removing and installing poly V-belt (Ti‐

guan)

♦ 4 mm Allen key
Removing
Note
Two tensioning elements must be slackened to remove poly V-

belt.
– Drain coolant; to do this, pull hose -2- off.

Item -1- can be disregarded.
– Release retaining clip and pull right connection (as seen in
direction of travel) off radiator.
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .

– To slacken poly V-belt, swing tensioning element in direction

of -arrow- from below using 16 mm open-end spanner.
– Lock tensioning element with a 4 mm Allen key -1-.
– Remove poly V-belt -2-.
Installing
Caution
Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.
– Fit poly V-belt first over crankshaft pulley. Finally, push belt
onto tensioning roller.
quence.
Add coolant ⇒ page 184 .
After completing repairs:
– Start engine, and check if belt runs properly.
1.4.1 Poly V-belt routing

Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Crankshaft pulley
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt

1.5 Removing and installing bracket for an‐

cillaries
Removing
Tiguan
Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat,
Passat CC, Golf Cabriolet
– Remove poly V-belt (Tiguan) ⇒ page 78 .
– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran,
Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
ing; Rep. gr. 87
Note

– Unscrew securing bolts -1- and remove bracket.
Installing
– Fit ancillary bracket to cylinder block.

– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 13 (page 72)
quence.
1.6 Renewing crankshaft oil seal - pulley end

equipment required
♦ Seal puller - 3203-

♦ Assembly sleeve - T10117/2-
♦ Assembly tool - T10053-

Removing
Tiguan
Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat,
Passat CC, Golf Cabriolet
– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
– Removing and installing crankshaft pulley ⇒ page 83 .
– Unscrew inner part of oil seal extractor - 3203- 3 turns (approx.
5 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove bearing bush from crankshaft journal and clean con‐
tact surfaces of crankshaft sprocket and bearing bush.
Installing
Note
♦ From model year 2009, a diamond coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
♦ Install a diamond coated washer -7- when a washer was not
fitted as original equipment ⇒ Electronic Parts Catalogue “ET‐
KA”.
♦ The washer is fitted -7- between the bearing bush -5- and the
crankshaft sprocket.
♦ Note that all contact surfaces from the securing bolt to the
crankshaft sprocket must be free of oil and grease.

– Clean sealing surfaces carefully. They must be free of oil and

grease.
1 - Securing bolt
2 - Crankshaft belt pulley
3 - Diamond coated washer (clipped onto crankshaft belt pulley)
4 - Crankshaft oil seal
5 - Bearing bush
6 - O-ring
7 - Diamond coated washer
– Push bearing bush onto crankshaft journal.
– Fit sleeve -T10117/2- onto bush and slide oil seal onto bush.
– Remove sleeve -T10117/2- from bush.
– Using assembly tool - T10053- , drive in oil seal into valve tim‐
ing housing as far as it will go with even blows of hammer.
quence.
1.7 Removing and installing crankshaft pulley


equipment required

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

♦ Dial gauge - VAS 6079-

♦ Dial gauge adapter - T10170- or dial gauge adapter - T10170
A-
Note
If the dial gauge adapter - T10170 A- is used, the ball head does
not need to be unscrewed from the dial gauge - VAS 6079- . The
ball head is fitted onto the flat side of the rod.
Removing
– Removing poly V-belt (Tiguan) ⇒ page 78 .
Polo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
Only Tiguan with all-wheel drive
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .
– Loosen pulley securing bolt. Hold pulley with counterhold -

3415- and -3415/1- .
Installing
– Tighten pulley hand-tight using a new securing bolt.
– Turn crankshaft in direction of engine rotation to TDC for No.

1 cylinder.

– Unscrew plug from crankcase.

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

tation.
Note
♦ Always use a new bolt.
Specified torque: 150 Nm + 1/2 turn (180°) further.

Hold pulley with counterhold - 3415- and -3415/1- .
– Unscrew locking pin - T10340- from crankcase.

– Screw plug into crankcase.
Specified torque: 30 Nm
– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Po‐
lo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .
– Install poly V-belt (Tiguan) ⇒ page 78 .
quence.

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 87
⇒ “2.2 Removing and installing sealing flange on gearbox side”,
page 89
2.1 Assembly overview - cylinder block,

gearbox end
Note
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

installing clutch .
1 - Securing bolt
crankshaft pulley
⇒ page 83
❑ Renew
❑ Contact surface for se‐
curing bolt must be free
of oil and grease.
❑ Oil threads before in‐
serting.
❑ Secure belt pulley
against turning with
counterhold - 3415- .
❑ The turning further an‐
gle can be measured
with a commercial pro‐
tractor.
2 - Belt pulley
❑ With diamond coated
washer
❑ Contact surfaces must
be free of oil and grease.
❑ Secure against turning
with counterhold - 3415-
when removing and in‐
stalling
❑ Remove poly V-belt (Ti‐
guan) ⇒ page 78 .
❑ Remove poly V-belt
(Golf Plus, Eos, Sciroc‐
co, Golf, Touran, Polo,
Sharan, Passat, Passat
CC, Golf Cabriolet)
⇒ page 75
3 - Seal
❑ Renew
4 - Bearing bush
5 - O-ring
❑ Renew
2. Cylinder block, gearbox end 87

6 - Cylinder block
7 - 60 Nm + 1/4 turn (90°) further
❑ Renew
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage when assembling.
10 - 12 Nm
❑ Renew
11 - Sealing flange with sender wheel and oil seal
❑ Removing and installing engine speed sender - G28- (not shown) ⇒ page 430 .
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 89 .

2.2 Removing and installing sealing flange on gearbox side

equipment required

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

wheel off crankshaft
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.

Procedure
– Remove flywheel or drive plate ⇒ Item 8 (page 88) .
– Set engine to TDC No. 1 cylinder ⇒ page 143 .
– Remove sump ⇒ page 171 .
– Remove engine speed sender - G28- -arrow-.
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together with 3 M6 × 35 mm bolts.
– Screw three M6×35 mm bolts into threaded holes -arrows- of

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

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

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

Assembly tool - T10134-

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

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

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

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

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

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

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

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

fixed in assembly device.
2.2.4 B - Fitting assembly tool - T10134- with

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

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

cylinder block.

2.2.5 C - Screwing assembly tool - T10134- on

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

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

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

position on crankshaft

♦ Ruler - T40100-

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

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

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

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

– Re-press sender wheel ⇒ page 96 .
If dimension -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 171 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm +1/4 turn (90°).

2.2.8 f) Re-pressing sender wheel

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

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

ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again ⇒ page 94 .
If dimension -a- is still too small:
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 94 .

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 97
⇒ “3.2 Pulling needle bearing out of and driving into crankshaft”,
page 98
⇒ “3.3 Crankshaft dimensions”, page 100
3.1 Assembly overview - crankshaft

For assembly work, secure engine in engine and gearbox bracket
- VAS 6095- .
1 - 50 Nm + 1/4 turn (90°) fur‐

ther
❑ Only tighten to 50 Nm
when measuring crank‐
shaft radial clearance.
Do not turn further.
2 - Bearing cap
❑ Do not interchange
bearing caps (mark po‐
sitions).
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
3 - Crankshaft
❑ Axial play, new: 0.07…
0.24 mm
❑ Wear limit: 0.26 mm
Check radial clearance with
Plastigage
❑ New: 0.03 … 0.05 mm
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Pulling needle bearing
out of and driving into
crankshaft
⇒ page 98 .
❑ Crankshaft dimensions
⇒ page 100 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 89 .
5 - 12 Nm
❑ Renew
6 - Thrust washers
❑ For bearing cap 3
3. Crankshaft 97
❑ Note fixing arrangement
7 - Bearing shell
❑ In cylinder block
8 - Sprocket
❑ For oil pump drive and timing chain.
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Pulling needle bearing out of and driving

into crankshaft
Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
♦ Drift - VW 207 C-

Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Installing
Note
The needle bearing must always be renewed after the gearbox

has been separated from the engine.
Condition:
• The front edges of the inner puller must be free of chips.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
3. Crankshaft 99
Installation depth: dimension -a- = 2.0 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

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

box; Installing gearbox .
3.3 Crankshaft dimensions

Honing Crankshaft Conrod
dimension in mm main journal ∅ journal ∅
Basic dimension -0.022 -0.022
54.00 47.80
-0.037 -0.037
Stage I -0.022 -0.022
53.75 47.55
-0.037 -0.037
Stage II --- -0.022
47.30
-0.037

4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 101
⇒ “4.2 Checking piston”, page 103
⇒ “4.3 Checking cylinder bores”, page 104
⇒ “4.4 Separating new conrod”, page 104
⇒ “4.5 Removing and installing pistons”, page 104
⇒ “4.6 Removing and installing oil spray jets”, page 105
4.1 Assembly overview - pistons and con‐

rods
Note
Oil all bearing and running surfaces before assembly.
1 - Retaining ring
2 - Piston pin
❑ If difficult to remove,
heat piston to 60°C.
❑ Remove and install us‐
ing drift - 10 - 14- .
3 - Piston
❑ Checking ⇒ page 103
❑ Mark installation posi‐
tion and cylinder num‐
ber.
Caution
Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring

clamp.
4 - Compression rings
❑ Offset gaps by 120°
❑ Remove and install
compression rings with
piston ring pliers.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 103 .
❑ Checking ring-to-groove
clearance ⇒ page 103 .
5 - Oil scraper rings
❑ Carefully remove and
install 3-part oil scraper
rings by hand.
❑ Checking ring gap ⇒ page 103 .
❑ Ring-to-groove clearance not measurable.
4. Pistons and conrods 101

6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.
❑ M8×1: 30 Nm + 1/4 turn (90°) further.
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
7 - Conrod bearing cap
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
8 - Bearing shell
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
Checking radial clearance with Plastigage:
❑ New: 0.020…0.060 mm
❑ Do not rotate crankshaft when checking radial clearance.
9 - 27 Nm
❑ Opening pressure of pressure relief valve: 1.8…2.2 bar
10 - Oil spray jet
❑ For piston cooling.
11 - Connecting rod
❑ Renew as set only.
❑ Markings -A-: mark with cylinder number
❑ Markings -B-: mark paired conrods and conrod bearing caps
❑ Separating new conrod ⇒ page 104 .
Caution
The conrod must be re‐
installed in exactly the
same position as it was
previously installed.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.
❑ Guided axially by piston.

4.2 Checking piston

♦ Micrometre 75 - 100 mm - VAS 6071-
Checking piston
– Measure pistons approx 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter max. 0.04 mm.
Piston ∅
Basic dimension mm 76.4601)
• 1) Measure approx. 12 mm from bottom of piston skirt
Checking piston ring gap

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

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

4.3 Checking cylinder bores

♦ Cylinder gauge - VAS 6078-
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Deviations compared with
nominal diameter max. 0.08 mm.
Cylinder bore ∅
Basic dimension mm 76.51
Note
Do not measure cylinder bores when cylinder block is mounted

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

On a new conrod, it is possible that the breaking point has not
fully separated. If the conrod bearing cap cannot be removed by
hand, proceed as follows:
– Mark cylinder allocation of conrod ⇒ Item 11 (page 102) .
– Gently clamp conrod, as shown in illustration, in a vice with
soft aluminium jaws.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.

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

ing cap in -direction of arrow- until it is loose.
4.5 Removing and installing pistons


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

Removing
– Remove cylinder head ⇒ page 116 .
– Mark piston installation position and corresponding cylinder
number ⇒ Item 3 (page 101) .
– Mark installation position and matching of cylinder and conrod
bearing cap to conrod ⇒ Item 7 (page 102) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
Install in reverse order of removal, observing the following:
Note
Renew bolts that are tightened with turning further angle.
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ Item 3 (page 101) .
– Install conrod bearing cap, observing installation position
⇒ Item 7 (page 102) .
– Install cylinder head ⇒ page 116 .
Specified torques
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 101
4.6 Removing and installing oil spray jets

♦ Allen key, long reach 5 mm - T10545-

Removing
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Remove oil pump ⇒ page 173 .
Note
♦ The crank web of the respective cylinder must be positioned

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

of engine rotation until the respective bolt is accessible.
– Unscrew pressure relief valve -1- using Torx bit T40 -
T10545- .
– Remove oil spray jets -2-.
Installing
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.
1- Pressure relief valve - 27 Nm

2- Oil spray jet
• Installation position: align leading edge of oil spray jet arrow
with machined surface of cylinder block.
– Install oil pump ⇒ page 173 .
– Install front right wheel housing liner ⇒ General body repairs;
Rep. gr. 66 ; Wheel housing liner; Removing and installing
front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head, oil all contact sur‐

faces between the support elements, roller rocker arms and
the cams before installing the camshaft housing.
♦ Do not remove the plastic packing pieces for protecting the
open valves until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
♦ Oil all bearing and running surfaces before assembly.
♦ Dismantling and assembling intake manifold ⇒ page 343
⇒ “1.1 Assembly overview - cylinder head”, page 107

⇒ “1.2 Removing and installing camshaft housing”, page 110
⇒ “1.3 Removing and installing cylinder head”, page 116
⇒ “1.4 Checking compression”, page 118
1.1 Assembly overview - cylinder head
1. Cylinder head 107

1 - 20 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
⇒ page 368
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
6 - Hall sender - G40-
❑ With O-ring
❑ Renew O-ring if dam‐
aged.
7 - Stud, 6 Nm
8 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
9 - Camshaft case
Note
The strainer for oil circuit must be

installed in cylinder head.
⇒ page 110
❑ Remove sealant residue.
❑ Carefully clean sealing surfaces. They must be oil and grease free.
❑ Before installing, coat with sealant - D 154 103 A1- .
❑ When installing, carefully fit onto dowel pins.
10 - 20 Nm
11 - Lifting eye
12 - Exhaust turbocharger
13 - Oil pressure switch - F1- , 20 Nm
❑ If seal is leaking, nip open and renew.
14 - Cylinder head gasket
❑ Renew
❑ Metal gasket.
❑ After renewing, renew entire coolant.
15 - Cylinder head
Note
The strainer for oil circuit must be

installed in cylinder head.
108 Rep. gr.15 - Cylinder head, valve gear

❑ Check for distortion ⇒ page 109 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
16 - Guide pin
17 - Dowel pin
18 - Oil strainer
❑ Inserted into cylinder head
❑ Renew
19 - Support element
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface
20 - Roller rocker fingers
❑ Check roller bearing for ease of movement.
❑ When installing, secure to supporting element using securing clip.
21 - Seal
Note
Note the different sealing types

when removing and installing the
camshaft housing ⇒ page 110 .
❑ Renew
❑ Qty. 4
❑ Inserted into cylinder head.
22 - Cylinder head bolt
❑ Renew
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 116 .
23 - Roller tappet
❑ Lightly coat contact surface with engine oil.
24 - O-ring
❑ Renew
❑ Moisten with oil before inserting.
Checking cylinder head for distortion

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

1.2 Removing and installing camshaft housing

equipment required

♦ Puller - T10094 A-
A-
♦ Camshaft clamp - T10171 A-
♦ Counter-hold tool - T10172-
♦ Adapter - T10172/1-
♦ Pin - T40011-

♦ Spark plug socket - 3122 B-

♦ Sealant - D 154 103 A1-
1.2.1 Removing
Note
♦ The camshafts are mounted in the camshaft housing on this

engine. Before removing camshaft housing, first remove valve
timing housing.
♦ Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf,
Polo, Sharan, Golf Cabriolet) ⇒ page 128 .
♦ Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
♦ Remove valve timing housing (Passat, Passat CC)
⇒ page 138 .
♦ The camshaft housing sealing surface cannot be reworked.
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– With ignition switched off, disconnect battery earth strap.
– Remove air filter (Eos, Golf Plus, Scirocco, Golf, Polo, Sharan,
Passat, Passat CC, Golf Cabriolet) ⇒ page 341 .
– Drain coolant (Sharan) ⇒ page 192 .
– Drain coolant (Passat, Passat CC) ⇒ page 197 .
– Remove coolant hoses and line/wiring guides.
– Remove turbocharger ⇒ page 281 .
– Remove regulating flap control unit ⇒ page 348 .
– Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf,
– Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .

– Remove valve timing housing (Passat, Passat CC)

⇒ page 138
– Turn crankshaft to TDC for No. 1 cylinder. Then turn crank‐
shaft 45° in engine direction and remove camshaft timing
sprockets with timing chain ⇒ page 145 .
– Unbolt camshaft sealing covers.
– Pull connectors off fuel pressure sender for low-pressure -
G410- and off high-pressure pump.
– Unscrew earth cable from camshaft housing.
– Remove ignition coils. Use puller -T10094 A- for this purpose
⇒ page 428 .
– Remove cable guide with wiring harness from camshaft hous‐
ing.
– Remove oil pressure switch - F1- -1-.
WARNING
– Pull connector and fuel supply line -arrows- off high-pressure

pump.
– Remove wiring guide -2- and remove connector -4- from Hall
sender - G40- .
Note
Use a spanner to counterhold threaded connections on high pres‐

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

– Pull out oil dipstick.
– Loosen camshaft housing bolts from outside to inside, alter‐
nately and diagonally and remove.
– Carefully lift camshaft housing off.

1.2.2 Installing
Condition
• The pistons cannot be positioned at TDC.
Note
The strainer for oil circuit must be installed in cylinder head.
– Remove sealant residues from cylinder head and camshaft

housing with a rotating brush, e.g. a hand drill with a plastic
brush (wear eye protection).
grease.
– Also prevent dirt and residual sealant from entering cylinder
head.
Caution
Before using camshaft clamp - T10171 A- you must check that

the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be inserted into holes in camshaft to stop.
– Screw in an M6 bolt hand-tight to secure camshaft clamp -
T10171 A- , but do not tighten.
Note
Camshaft housings with different sealing variants in area of spark

plug recess have been fitted.
Sealing on cylinder head with no sealing ring in area of spark plug

recess
Caution
No sealant is applied in area of the oil strainer -1-.

– Apply thin, even coat of sealant on clean camshaft housing

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

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

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

sealing surface. See hatched area in illustration.
– Do not apply sealant in area of -arrows-.
Sealing on cylinder head with machined chamfer in area of spark
plug recess
Caution
– Apply thin, even coat of sealant - D 154 103 A1- on clean

camshaft housing sealing surface. See hatched area in illus‐
tration.
– Apply sealant -D 176 600 A1- to the chamfer -arrows- of cyl‐
inder head.
The sealant bead must be 2 mm thick.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Caution
Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective sup‐
port elements -2-.
Proceed with extreme caution when fitting the camshaft hous‐
ing onto the cylinder head in order to prevent the roller rocker
fingers from sliding down!

– When fitting camshaft housing onto cylinder head, first fit cam‐
shaft housing at angle shown in illustration onto dowel pins
-arrows-.
– Then, carefully lower camshaft housing in

-direction of arrow- towards cylinder head.
Note
Ensure that no oil residue can drip onto sealing surfaces.
– Evenly tighten new camshaft housing securing bolts from in‐

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

the sealant to dry.
– Adjust valve timing ⇒ page 145 .

quence. During this procedure, observe the following:
♦ Install valve timing housing (Eos, Golf Plus, Scirocco, Golf,
Polo, Sharan, Golf Cabriolet) ⇒ page 128
♦ Installing valve timing housing (Tiguan, Touran) ⇒ page 132
♦ Installing valve timing housing (Passat, Passat CC)
⇒ page 138
♦ Install regulating flap control unit ⇒ page 348 .
♦ Install turbocharger ⇒ page 281 .
♦ Install crankshaft belt pulley ⇒ page 83 .
♦ Attaching fuel lines ⇒ page 368

Specified torque
Component Specified torque
Oil pressure switch - F1- 20 Nm
1.3 Removing and installing cylinder head

equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8- (Golf Plus, Eos)
♦ Adapter - 10 - 222 A /22- (Tiguan)
♦ Bracket - T10358-
1.3.1 Removing
Remove following components:
♦ Removing and installing valve timing housing (Eos, Golf Plus,
Golf, Scirocco, Polo, Sharan, Golf Cabriolet) ⇒ page 128

♦ Removing and installing valve timing housing (Tiguan, Tour‐

an) ⇒ page 132
⇒ page 138
♦ Remove thermostat housing from cylinder head.
♦ Remove timing chain ⇒ page 159
♦ Remove turbocharger ⇒ page 281 .
♦ Remove regulating flap control unit - J808- and throttle valve
module - J338- ⇒ page 348 .
♦ Removing intake manifold ⇒ page 343 .
– Unscrew securing bolt for gearbox and attach bracket -
T10358- as shown.
– Attach hooks of support bracket - 10 - 222 A- to bracket -
T10358- as shown.
– Turn spindle until the hooks are lightly tensioned.
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
Removing and installing camshaft housing ⇒ page 110 .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
– Loosen cylinder head bolts in sequence given and then re‐

move completely.
– Carefully remove cylinder head.
1.3.2 Installing
Condition
• The pistons cannot be positioned at TDC.

Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
♦ The strainer for oil circuit must be installed in cylinder head.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set No. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.
– Tighten cylinder head in sequence as follows:
Specified torque/turning further angle
Stage Specified torque
1 30 Nm
2 Turn 90° further using rigid
wrench
wrench
wrench
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Install camshaft housing.
Removing and installing camshaft housing ⇒ page 110 .
quence.
1.4 Checking compression


equipment required

♦ Compression tester - V.A.G 1763-
Prerequisites for check
• The engine oil temperature must be at least 30 °C.
Procedure
– Remove engine cover panel.
– Remove ignition coils. Use puller - T10094 A- for this purpose.
– Unscrew spark plugs with spark plug socket and extension -
3122 B- ⇒ page 428 .
– Remove fuse for fuel pump control unit voltage supply from
fuse holder beneath left dash panel ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

Note
Removing fuse interrupts voltage supply for fuel pump control

unit.
– Check compression using compression tester - V.A.G 1763- ,

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

crease.
Compression pressures:
New bar pressure Wear limit bar pres‐ Difference between
sure cylinders bar pres‐
sure
10.0 … 15.0 7.0 max. 3.0
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 25 Nm.
quence.
– Read event memory, rectify any faults and then clear event
memory: ⇒ Vehicle diagnostic tester “Guided Fault Finding”.
The readiness code must be generated if the event memory has
been cleared.

2 Valve gear
⇒ “2.1 Assembly overview - valve gear”, page 121
⇒ “2.2 Measuring axial clearance of camshaft”, page 123
⇒ “2.3 Reworking valve seats”, page 123
⇒ “2.4 Checking valve guides”, page 125
⇒ “2.5 Removing and installing valve stem seals”, page 125
2.1 Assembly overview - valve gear
1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ Left-hand thread
❑ Renew
2 - Camshaft adjuster
❑ Must not be dismantled.
⇒ page 145
3 - Camshaft sprocket
❑ Note position when in‐
stalling timing chain.
4 - O-ring
❑ Renew if damaged
❑ Before installing, coat
lightly with engine oil.
5 - Inlet camshaft control valve
1 - N205-
6 - 10 Nm
7 - 10 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ Tighten from inside out‐
wards.
8 - Camshaft case
⇒ page 110
❑ Remove sealant resi‐
due.
❑ Before installing, coat
with sealant - D 154 103
A1- .
❑ When installing, carefully fit onto dowel pins from above.
9 - 10 Nm
10 - Cap
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker fingers
❑ Check roller bearing.
❑ When installing, secure to supporting element using securing clip.
2. Valve gear 121

12 - Valve cotters
13 - Valve stem seal
❑ Renew
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Before installing, check camshaft axial clearance ⇒ page 123 .
15 - Valve guide
16 - Valve springs
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ page 125 .
17 - Cylinder head
❑ Reworking valve seats ⇒ page 123 .
❑ Reworking sealing surface ⇒ page 122 .
18 - Valves
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ page 123
19 - Exhaust camshaft
❑ Do not interchange with inlet camshaft.
❑ Checking axial clearance ⇒ page 123 .
❑ Coat with oil before inserting (also axial bearing shoulder).
20 - Guide bush
21 - Inlet camshaft
❑ With cam for high-pressure pump
❑ Before removing, remove and renew bucket tappet for high-pressure pump.
❑ Do not interchange with exhaust camshaft.
❑ Checking axial clearance ⇒ page 123 .
❑ Coat with oil before inserting (also axial bearing shoulder).
22 - 50 Nm + 1/4 turn (90°) further
❑ Renew
Reworking cylinder head sealing surface

Cylinder head reworking dimension: a = at least 108.25 mm
Note
When the sealing surface has been reworked, the valves must be
set deeper by the same amount (valve seat inserts reworked) or
valves will contact pistons. When doing this, ensure that the per‐
missible minimum dimension is maintained ⇒ page 123 .

2.2 Measuring axial clearance of camshaft

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

∅a mm 29.5 26.0
∅b mm 5.973 5.953
c mm 100.9 100.5
α ∠° 45 45
2.3 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
2. Valve gear 123

Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 125 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
The max. permissible reworking dimension is calculated as fol‐

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

for the calculation.
– Measure distance between end of valve stem and upper edge

of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance and minimum dimension.
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
-Measured distance 8.0 mm
Minimum dimension 7.6 mm
=max. perm. rework dimension1) 0.4 mm
1) The max. permissible reworking dimension is shown as dimension “b” in the
illustrations for reworking valve seats.
Reworking inlet valve seat

a = ∅ 28.7 mm
b = Max. permissible reworking dimension1
c = 1.5…1.8 mm
Z = Cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
2) Calculating max. permissible reworking dimension ⇒ page 123 .
Reworking exhaust valve seat
a = 25.0 mm ∅
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
3) Calculating max. permissible reworking dimension ⇒ page 123 .

2.4 Checking valve guides

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

seals
♦ Spark plug socket - 3122B-
2. Valve gear 125

♦ Valve stem pliers - VAS 6770-
♦ Valve spring tool - 3362- with thrust piece - 3362/1-
♦ Valve stem seal fitting tool - 3365-
♦ Pressure hose - VW 653/3-
Removing
2.5.1 Removing
(With cylinder head installed)
Removing and installing valve timing housing (Eos, Golf Plus,

Removing and installing valve timing housing (Tiguan, Touran)

⇒ page 132
Remove valve timing housing (Passat, Passat CC) ⇒ page 138
– Remove camshaft housing ⇒ page 110 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .
– Screw pressure hose - VW 653/3- into spark plug thread.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem pliers - VAS 6770- .
2.5.2 Installing
– Place plastic sleeve supplied on respective valve stem. This
will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft housing ⇒ page 113 .
♦ Removing and installing valve timing housing (Eos, Golf Plus,
♦ Removing and installing valve timing housing (Tiguan, Tour‐
an) ⇒ page 132
⇒ page 138
♦ Install fuel lines ⇒ page 368
2. Valve gear 127

3 Cover for timing chain

⇒ “3.1 Removing and installing valve timing housing (Eos, Golf
Plus, Scirocco, Golf, Polo, Sharan, Golf Cabriolet)”, page 128
⇒ “3.2 Removing and installing valve timing housing (Touran, Ti‐
guan)”, page 132
⇒ “3.3 Removing and installing valve timing housing (Passat CC,
Passat)”, page 138
3.1 Removing and installing valve timing housing (Eos, Golf Plus, Scirocco,
Golf, Polo, Sharan, Golf Cabriolet)

equipment required
♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /8-
♦ Pin - 3415/1-


♦ Silicone adhesive sealant - D 176 501 A1-
3.1.1 Removing
rection of -arrow-.
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Mark the direction of rotation of the poly V-belt and remove
belt ⇒ page 75 .
– Turn crankshaft in direction of engine rotation to TDC for no.
1 cylinder ⇒ page 143 .
– Remove coolant pump ⇒ page 213 .
– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove air conditioner compressor from bracket with refrig‐
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Remove bracket for tensioning element and air conditioner
compressor.
– Remove alternator.
Scirocco
– Install support device - 10 - 222 A- with adapter - 10 - 222 A /

8- as shown and hook into lifting eye.
– Position adapter - 10 - 222 A /8- on vehicle front end
-arrows- as shown.
All vehicles
3. Cover for timing chain 129

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

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

-arrows-.
– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .
– Remove Allen head bolts for valve timing housing and hexa‐
gon bolts indicated by -arrows-.
– Remove valve timing housing.
Note
Note that crankshaft bearing bush remains in sealing flange.

3.1.2 Installing
Note

KA”.

grease.
1 - Securing bolt
5 - Bearing bush
6 - O-ring
Note
♦ Timing housing is still sealed to engine with a gasket and ad‐

ditionally with silicone adhesive sealant - D 176 501 A1- .
♦ Silicone adhesive sealant - D 176 501 A1- prevents leaks be‐
tween timing housing and joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.
♦ Do not apply sealant until directly before the valve timing
housing is fitted.

– Apply silicone adhesive sealant - D 176 501 A1- to joints be‐

tween camshaft housing and cylinder head -1- and between
cylinder head and cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two -M6x80- studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
– Tighten valve timing housing securing bolts evenly and diag‐
onally.
Ensure that valve timing housing is not canted.
Specified torque:
M6 bolt to 10 Nm
M10 bolt to 50 Nm
Eos, Golf Plus, Scirocco, Golf, Golf Cabriolet, Sharan

Polo
– Rock engine to align engine mountings stress-free.
Install crankshaft belt pulley ⇒ page 83 .
quence.
3.2 Removing and installing valve timing housing (Touran, Tiguan)


equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /22-
♦ Pin - 3415/1-

♦ Adapter - 10 - 222 A /26- (for Touran)

♦ Adapter - 10-222A/30- (for Touran)
♦ Hook - 10 - 222 A /10- (for Touran)
♦ Shackle - 10 - 222 A /12- (for Touran)
♦ Silicone adhesive sealant - D 176 501 A1-
Note
♦ The Touran has different versions of the front end.

♦ The shape of the headlights is a distinguishing characteristic.
♦ Determine which version of the front end is at hand and use
the correct adapters accordingly.
Vehicles ► 11.06
Small headlights -arrow 1-: adapter - 10-222A/22- .

Vehicles from 12.06 ► 05.10
Large headlights with curve -arrows 2-: adapter - 10-222A/26- .
Vehicles 06.10 ►
Large headlights without curve -arrow 3-: adapter - 10-222A/30- .

3.2.1 Removing
rection of -arrow-.
housing liner .
– Mark direction of rotation of poly V-belt and remove it (Tiguan)
⇒ page 78 .
– Mark direction of rotation of poly V-belt and remove it (Touran)
⇒ page 75 .
– Turn crankshaft in direction of engine rotation to TDC for no.
– Remove coolant pump ⇒ page 213 .
– Remove banjo bolt from oil supply pipe to turbocharger.
– Remove ancillary bracket ⇒ page 80 .
Tiguan
– Support bracket - 10 - 222 A- with adapter - 10 - 222 A /22-

Touran
Note
Observe distinguishing characteristics of the front end

⇒ page 134 .
– Fit engine support bracket - 10-222A- with adapter - 10 - 222

A /26- and take up weight of engine in installation position.


-arrows-.
– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .
– Remove Allen head bolt for control housing and hexagon bolts
indicated by -arrows-.
Note

3.2.2 Installing
Note

KA”.

grease.
1 - Securing bolt
5 - Bearing bush
6 - O-ring
Note
♦ Timing housing is still sealed to engine with a gasket and ad‐

ditionally with silicone adhesive sealant - D 176 501 A1- .
♦ Silicone adhesive sealant - D 176 501 A1- prevents leaks be‐
tween timing housing and joints -1- and -2-.
of approx. 1 mm.
housing is fitted.

– Apply silicone adhesive sealant - D 176 501 A1- to joints be‐

tween camshaft housing and cylinder head -1- and between
cylinder head and cylinder block -2-.
– Fit new gasket onto dowel pins.
– When fitting, install two “M6x80” studs into cylinder head and
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
taneously onto studs, dowel pins and crankshaft journal.
onally.
Ensure that valve timing housing is not canted.
Specified torque:
M6 bolt to 10 Nm
M10 bolt to 50 Nm

quence.
3.3 Removing and installing valve timing housing (Passat CC, Passat)


equipment required
♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /22-
♦ Pin - 3415/1-
♦ Torque wrench (5 … 50 Nm) - V.A.G. 1331-
♦ Torque wrench (40 to 200 Nm) - V.A.G. 1332-
♦ Sealant - D 176 501 A1-
Removing

rection of -arrow-.
– Remove crankcase breather on union of valve timing housing.
– Remove noise insulation or skid plate ⇒ General body repairs,
or skid plate .
housing liner .
– Mark direction of rotation of poly V-belt and remove it
⇒ page 75 .
– Drain coolant
⇒ “1.8 Draining and filling coolant (Passat, Passat CC)”, page
197 .
– Remove coolant pump
⇒ “2.10 Removing and installing coolant pump (Passat, Passat
CC)”, page 241 .
– Turn crankshaft in engine direction of rotation to TDC for No.
– Unscrew banjo bolt of turbocharger oil supply pipe on valve
timing housing ⇒ Item 16 (page 281) .
– Remove bracket for ancillaries ⇒ page 80 .
– Position support bracket - 10 - 222 A- with adapter - 10 - 222

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

The wing will otherwise be damaged.

-arrows-.

– Undo bolt for poly V-belt. Hold pulley with counterhold - 3415-
and -3415/1- .
– Undo socket bolts of valve timing housing.

– Undo the marked socket bolts -arrows-.
Note
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
Note that belt pulley contact surfaces, securing bolt, bearing bush
and crankshaft sprocket must be free of oil and grease.
Clean sealing surfaces carefully.

The sealing surfaces must be free of oil and grease.
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
of approx. 1 mm.
housing is fitted.

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

cylinder head -1- and cylinder head/cylinder block -2-.
– Place new seal onto dowel pins.
– Screw two -M6x80- studs into cylinder head and cylinder block
to improve guidance.
– Fit timing housing with crankshaft bearing bush simultaneous‐
ly onto studs, dowel pins and crankshaft journal.
onally.
Ensure that timing housing is not canted.
Specified torque
M6 bolt to 10 Nm
M8 bolt to 20 Nm
M10 bolt to 50 Nm

Engine mounting specified torque ⇒ page 67
Install poly V-belt ⇒ page 75 .

4 Chain drive
⇒ “4.1 Checking valve timing”, page 143
⇒ “4.2 Adjusting valve timing”, page 145
⇒ “4.3 Checking timing chain”, page 152
⇒ “4.4 Removing and installing timing chain and chain drive for
oil pump”, page 159
4.1 Checking valve timing

equipment required

A- (observe note ⇒ page 144 ).
4. Chain drive 143

Note
The mounting points for securing the camshaft clamp were modi‐
fied. A new special tool designated camshaft clamp - T10171 A-
has been introduced. Previous camshaft clamp - T10171- can
continue to be used if processed as described in the following.
– Place template -1- onto camshaft clamp - T10171- as shown.

– Mark camshaft clamp - T10171- at mark -2- using a centre
punch.
– Drill through camshaft clamp - T10171 - using a 7 mm bit.
– Deburr hole on both sides.
– Additionally mark tool designation -T10171- with an -A-.
Test sequence
– Remove lower part of front right wheel housing liner ⇒ General
– Remove spark plug from No. 1 cylinder. To do this, use puller
- T10094 A- and spark plug socket and extension - 3122 B-
⇒ page 428 .

– Then remove bolts for both camshaft covers -3-.
– Unclip engine pre-wiring harness -1-.

– Pull coolant pipe -2- and engine pre-wiring harness -1- away
from cylinder head.
– Remove both bolts -3- from cylinder head.
Note

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

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

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

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

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

ings.
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
tion “TOP” -arrow 3- must be readable from above.
If camshaft clamp - T10171 A- cannot be inserted into camshaft
openings to stop, then timing is incorrect and must be readjusted
⇒ page 145 .
Timing is OK if camshaft clamp - T10171 A- can be fitted into
camshaft openings to stop.
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
Specified torque
4.2 Adjusting valve timing
4. Chain drive 145


equipment required

♦ Pin - T40011-


♦ Locating bolt - T10340-
Procedure
– Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf,
– Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
– Remove valve timing housing (Passat, Passat CC)
⇒ page 138
4. Chain drive 147

– To turn crankshaft, reinstall bearing bush, crankshaft pulley

-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counterhold - 3415- ).
⇒ page 428 .


from cylinder head.
Note

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
stop and lock in position with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC for No.
1 cylinder. Note position of small needle on dial gauge.
– Then turn crankshaft 2 revolutions in engine direction of rota‐
tion.

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

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

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

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

T10171 A- can be inserted into holes in camshaft to stop.
Note
Do not push camshafts axially whilst turning.
4. Chain drive 149

– Screw M6 bolt hand-tight into corresponding bore -arrows- (do

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

use counterhold - T10172- for this.
Note
Do not use camshaft clamp - T10171 A- as a counterhold.
– Remove one camshaft sprocket.
Caution
If the camshaft adjuster has been removed, the guide sleeve

must seat in the camshaft when installing!
– Place timing chain over camshaft sprockets, observing chain

direction of rotation, and install camshaft sprocket again.
– Tighten camshaft bolts until camshaft sprockets can still just
be turned on camshafts.
– Tension timing chain by removing locking pin - T40011- .
– Turn crankshaft in direction of engine rotation to TDC No. 1

cylinder. Permissible deviation from TDC No. 1 cylinder:
±0.01 mm.
Note
If crankshaft is turned more than 0.01 mm past TDC, turn crank‐

shaft two full turns in direction of engine rotation to set crankshaft
at TDC for No. 1 cylinder.
Only Tiguan with all-wheel drive

drive shafts .
– Unscrew plug -arrow- from crankcase.


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

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

– Rotate crankshaft two full turns in direction of engine rotation
to TDC No. 1 cylinder. Permissible deviation from TDC No. 1
cylinder: ± 0.01 mm.
Caution

be renewed.

ings.
If camshaft clamp - T10171 A- cannot be fitted:
– Repeat adjustment.
If camshaft clamp - T10171 A- can be inserted:
4. Chain drive 151


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

ets with counterhold - T10172- and tighten bolts -2- (left-hand
thread) and -4- 1/4 turn (90°) further with a rigid wrench.
Note
♦ Camshaft adjuster centre bolt -2- has a left-hand thread.

♦ Camshaft sprockets cannot move on camshaft whilst tighten‐
ing.

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

crankshaft pulley is installed.
♦ Install valve timing housing (Eos, Golf Plus, Golf, Scirocco,

Polo, Sharan, Golf Cabriolet) ⇒ page 131
♦ Installing valve timing housing (Tiguan, Touran) ⇒ page 137
♦ Installing valve timing housing (Passat, Passat CC)
⇒ page 138
♦ Install crankshaft belt pulley ⇒ page 83 .
♦ Install poly V-belt (Tiguan) ⇒ page 78 .
♦ Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Po‐
lo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
Specified torque
4.3 Checking timing chain


♦ Torque wrench - VAS 6583-
♦ Tester for checking elongation of chain links - T10550-
♦ Camshaft clamp - T10550/1-

♦ Indicator - T10550/2-
♦ Scale sleeve - T10550/3-
• The engine oil temperature must be at least 40°C ⇒ Vehicle
diagnostic tester.
• The engine must necessarily not be at »TDC« position.
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .
– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise
insulation; Assembly overview - noise insulation .
– Remove front right wheel housing liner: ⇒ General body re‐
housing liner .
Vehicles with condensate trap on charge air pipe
– Open clamps -arrows-.
– Pull coolant hoses -1- off charge air pipe -2-, and clamp them
off using hose clips up to 40 mm - 3093- .
4. Chain drive 153

Vehicles with engine preheating element - Z97-

Vehicles with auxiliary/supplementary heater:

– Open hose clips, and pull coolant hoses off coolant pipes -1-.
– Remove auxiliary/supplementary heater with exhaust pipe
and coolant hoses still connected ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; auxiliary/supplementary heater;
Removing and installing auxiliary/supplementary heater .

– Pull off securing clip on charge air cooler in
– Pull charge air hose -arrow- off charge air cooler.
– Remove securing bolt -arrow- for charge air pipe -1-.

– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Unscrew securing bolt -arrow- for charge air pipe -1-.
– Lift off engine cover at points -1- and pull it forwards in direction
of -arrow-.
– Remove air filter housing ⇒ page 341 .
– Pull off fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing release tabs.
4. Chain drive 155

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.
– Unscrew hose clip -1- on charge air pipe.

– Open hose retainer -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
nector from charge air pressure sender - G31- with intake air
temperature sender 2 - G299- .
– To do this, unscrew bolts -arrows-.

– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.

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

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

positioned as shown in the illustration.
– If necessary, turn crankshaft in direction of engine rotation.
– Insert camshaft clamp - T10550/1- to stop in camshaft open‐

ings.
– The locking pin -arrow A- must engage in hole -arrow B- in
exhaust camshaft.
– Inscription “TOP” must be readable from above.
4. Chain drive 157

– Bolt on camshaft clamp - T10550/1- hand-tight.

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

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

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

shown in illustration.
– Apply torque wrench - VAS 6583- with a suitable socket to

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

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

slowly anti-clockwise.
– Maintain a torque of 40 Nm on torque wrench - VAS 6583- .
– Read value on the scale.
– If the chain skips during the test, renew timing chain
⇒ page 159 .
– If the chain skips, it can be heard and felt clearly.
Evaluation of the test
– If a chain elongation of up to 28° has been determined during
the test, the timing chain is OK.
– If a chain elongation of 29° and more has been determined,
the timing chain is not OK and must be renewed
⇒ page 159 .
Assemble in reverse order of dismantling. During this procedure,
observe the following:
Note
♦ The scale sleeve - T10550/3- is equipped with magnets.

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

that indicator - T10550/2- is not positioned within range of
scale.
– Grasp behind scale sleeve - T10550/3- with both hands.
– Press thumbs against bolt of belt pulley, and pull off scale
sleeve - T10550/3- .
– Renew oil seals for camshaft sealing cover and oil them before
fitting.
Specified torques
♦ ⇒ “1 Air filter”, page 339
♦ ⇒ “2.1 Assembly overview - valve gear”, page 121
♦ ⇒ “3 Charge air system”, page 318
♦ ⇒ “2.1 Assembly overview - supercharger”, page 296
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 71
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly over‐
view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
4.4 Removing and installing timing chain and chain drive for oil pump
4. Chain drive 159


equipment required

♦ Pin - T40011-


Removing
rection of -arrow-.
– Remove air filter (Golf, Golf Plus, Eos, Scirocco, Touran, Ti‐
guan, Sharan, Passat, Passat CC, Golf Cabriolet)
⇒ page 341 .
– Drain coolant (Golf, Golf Plus, Eos, Scirocco, Touran, Tiguan,
Golf Cabriolet) ⇒ page 184 .
– Remove coolant hoses and line/wiring guides -arrows-.

– Unscrew securing bolts of camshaft cover -1-.
⇒ page 428 .

4. Chain drive 161


from cylinder head.
Note

stop.
– Insert dial gauge - VAS 6079- as far as stop and lock it in po‐
sition with lock nut -arrow-.
– Turn crankshaft in direction of engine rotation, to TDC No. 1
cylinder. Note position of small needle on dial gauge.
The bores -arrows- in the camshafts must be as illustrated. If

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

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

be renewed.

ings.

– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 A- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 A- .
Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Po‐
lo, Sharan, Golf Cabriolet) ⇒ page 128 .
Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
– Pull cover -1- off sprocket for oil pump.
– Press tensioning rail in -direction of arrow- by hand and lock

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

tip marker pen.
Caution
Camshaft adjuster securing bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .
4. Chain drive 163

– Hold oil pump sprocket with counterhold - T10172- and loosen

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

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

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

nal as far as the stop.
Caution
Cast lug -2- on sprocket -1- must seat in groove -3- on crank‐
shaft journal.

– Mark position of sprocket and crankshaft to cylinder block us‐

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

♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
position -arrow-.
– Hold oil pump drive sprocket with counterhold - T10172- .

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

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

♦ The crankshaft must remain stationary.
– Tighten sprocket -3- hand-tight with new securing bolt.
4. Chain drive 165

– Place timing chain -1- on crankshaft sprocket -4-, exhaust

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

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

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

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

– Unscrew bolt -arrow- and remove camshaft clamp - T10171

A- from camshaft housing.
– Check valve timing ⇒ page 143
If valve timing is OK:
– Hold camshaft sprockets with counterhold - T10172- and tight‐

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

Remove valve timing housing (Eos, Golf Plus, Scirocco, Golf, Po‐
lo, Sharan, Golf Cabriolet) ⇒ page 128 .
Remove valve timing housing (Tiguan, Touran) ⇒ page 132 .
– Install crankshaft pulley ⇒ page 83 .
– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Po‐
lo, Sharan, Passat, Passat CC, Golf Cabriolet) ⇒ page 75 .

quence.
Specified torque
4. Chain drive 167

17 – Lubrication
1 Sump, oil pump
Note
♦ Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the conrod bear‐
ings are damaged. To prevent this from causing further
damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renewing oil filter
♦ The oil level must remain below the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 171 .
⇒ “1.1 Engine oil:”, page 168

⇒ “1.2 Assembly overview - sump, oil pump”, page 168
⇒ “1.3 Removing and installing sump”, page 171
⇒ “1.4 Removing and installing oil pump”, page 173
1.1 Engine oil:

Oil capacities (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cab‐
riolet, Polo)
With oil filter 3.6 l
Oil capacities (Tiguan, Sharan)
With oil filter 4.0 l
Engine oil specifications
⇒ Maintenance ; Booklet ; Service tables
Changing engine oil: “Engine oil: Drain or extract”
⇒ Maintenance ; Booklet ; Service tables
1.2 Assembly overview - sump, oil pump
168 Rep. gr.17 - Lubrication

1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 171 .
2 - Engine oil cooler
Note
♦ To remove:
♦ Drain coolant ⇒ page 179 .
♦ Remove coolant pipe
⇒ Item 4 (page 169) .
♦ Remove engine oil cooler.
♦ Install in reverse order of remov‐
al.
3 - O-ring
❑ Renew
4 - Coolant pipe
❑ For engine oil cooler
❑ Specified torque, brack‐
et to crankcase: 20 Nm.
5 - 8 Nm
6 - Cap
❑ Renew seal if damaged.
7 - Seal
8 - Oil filter, 20 Nm
❑ Loosen with oil filter tool
- 3417- .
❑ Observe fitting instructions on oil filter
❑ With non-return valve
9 - Valve timing housing
❑ Additionally install with silicone adhesive sealant - D 176 501 A1- .
Removing and installing valve timing housing (Eos, Golf Plus, Golf, Scirocco, Polo, Sharan, Golf Cabriolet)
⇒ page 128
Removing and installing valve timing housing (Tiguan, Touran) ⇒ page 132

❑ When installing, install two -M6x80- studs in cylinder block and camshaft housing as a guide.
❑ To guide valve timing housing, secure sump in position with two bolts.
10 - 10 Nm
11 - Securing bolt
❑ Renew
1. Sump, oil pump 169

12 - Belt pulley
❑ Contact surfaces of pulley must be free of oil and grease.
❑ Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat
CC, Golf Cabriolet) ⇒ page 75
❑ Removing and installing poly V-belt (Tiguan) ⇒ page 78
13 - Seal
❑ Renew
14 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
15 - Seal
16 - Sprocket
❑ For oil pump drive.
17 - 20 Nm + 1/4 turn (90°) further
❑ Renew
18 - Sprocket
❑ For oil pump.
❑ Lock with counterhold - T10172- .
19 - Drive chain
❑ For oil pump.
❑ Before removing, mark direction of rotation (installation position).
20 - 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
22 - Oil drain plug, 30 Nm
❑ With captive seal
❑ Renew
23 - 13 Nm
❑ Loosen and tighten flywheel end bolts only with long-reach Allen key - T10058- .
24 - 40 Nm
25 - Oil pan
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 600 A1- .

26 - 14 Nm + 1/4 turn (90°) further

27 - Oil pump
Caution
The oil supply line must
be renewed on the tur‐
bocharger if a new oil
pump or oil suction pipe
is fitted.
❑ with oil suction pipe

❑ Specified torque oil suction pipe: 9 Nm
28 - 2 Nm + 1/4 turn (90°) further
29 - Oil separator
Markings on oil dipstick

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


♦ Hand drill with plastic brush

♦ Scraper
♦ Safety glasses
♦ Silicone sealant - D 176 600 A1-
Removing
Polo
– Remove catalytic converter with front silencer ⇒ page 423 .
– Unbolt front exhaust pipe ⇒ page 415 .
– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.

– On the gearbox side, two screws may not be immediately ac‐
cessible. If the screw heads cannot be reached with a bit -
T10058- , turn the crankshaft in the engine direction until the
screws are accessible. The flywheel is provided with recesses.
– Remove sump. Loosen sump with light blows of a rubber-
headed hammer if necessary.
– Remove sealant residue from cylinder block with a flat scraper.

– Remove sealant residue on sump with a rotating brush, e.g.

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

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted into the cylinder block flange at two
positions as guides.
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

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

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

– Tighten oil sump bolts to 13 Nm.
Specified torque for oil pan securing bolts to gearbox: 40 Nm
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.

quence.
1.4 Removing and installing oil pump
Caution
The oil supply line must be renewed on the turbocharger if a

new oil pump or oil suction pipe is fitted.

Removing
– Pull cover -1- off sprocket for oil pump.
– Hold oil pump sprocket with counterhold - T10172- .
– Loosen sprocket securing bolt.
Note
Do not remove bolt completely.
– Press chain tensioner in direction of -arrow- with a screwdriv‐

er.
– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.

– Loosen oil pump securing bolts -arrows- and remove them.

– Remove oil pump from cylinder block.
Installing
Caution
The oil supply line must be renewed on the turbocharger if a

new oil pump or oil suction pipe is fitted.
– Install oil pump and tighten securing bolts to 14 Nm + 1/4 turn

(90°) further.
Specified torque oil suction pipe: 9 Nm
– Press chain tensioner in direction of -arrow- with a screwdriv‐

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

-arrows-.
– Screw in sprocket securing bolt.
– Hold sprocket with counterhold - T10172- .
– Position torque wrench - V.A.G 1331- as shown.

– Tighten securing bolt to 20 Nm +1/4 turn (90°) further.

– Install cover -1-.


2 Oil filter, oil pressure switch
2.1 Checking oil pressure and oil pressure switch

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

♦ Voltage tester - V.A.G 1527B-
♦ Adapter set - V.A.G 1594C-
♦ 10 mm jointed spanner - T40175-
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
The oil pressure switch is located on the gearbox side beneath
the two camshaft covers.
2. Oil filter, oil pressure switch 177

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

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

19 – Cooling
1 Cooling system/coolant
Caution
♦ Observe the following points during all installation work, in

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

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

V.A.G 1274 B- and adapter for cooling system tester - V.A.G
1274/8- and adapter for cooling system tester - V.A.G 1274/9- .
⇒ “3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus,
Scirocco, Golf, Touran, Golf Cabriolet)”, page 255
⇒ “1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco,
Golf, Touran, Polo, Golf Cabriolet)”, page 180
⇒ “1.2 Schematic diagram for coolant hoses (Tiguan)”,
page 181
⇒ “1.3 Schematic diagram for coolant hoses (Sharan)”,
page 182
⇒ “1.4 Coolant hose schematic diagram (Passat, Passat CC)”,
page 183
⇒ “1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco,
Golf, Touran, Tiguan, Golf Cabriolet)”, page 184
⇒ “1.6 Draining and filling coolant (Polo)”, page 188
⇒ “1.7 Draining and filling coolant (Sharan)”, page 192
⇒ “1.8 Draining and filling coolant (Passat, Passat CC)”,
page 197
⇒ “1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus,
Eos, Scirocco, Golf, Golf Cabriolet)”, page 203
1. Cooling system/coolant 179

⇒ “1.10 Checking cooling system for leaks (Sharan, Tiguan)”,

page 205
⇒ “1.11 Checking cooling system for leaks (Passat, Passat CC)”,
page 207
1.1 Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran,
Polo, Golf Cabriolet)
1 - Expansion tank
2 - Coolant pump
3 - Intake manifold
4 - Cylinder head and cylinder
block
❑ If renewed, refill system
with fresh coolant.
5 - Heat exchanger for heater
6 - Thermostat housing
7 - Radiator/cooler
9 - Coolant circulation pump -
V50-
⇒ page 222
⇒ page 281
11 - Circulation pump - V55-
❑ Optional equipment
12 - Auxiliary heater
180 Rep. gr.19 - Cooling

1.2 Schematic diagram for coolant hoses (Tiguan)
1 - Expansion tank
2 - Intake manifold
6 - Radiator/cooler
V50-
⇒ page 222
⇒ page 281
block
with fresh coolant.

1.3 Schematic diagram for coolant hoses (Sharan)
1 - Expansion tank
2 - Intake manifold
4 - Gear oil cooler
❑ Only vehicles with a du‐
al clutch gearbox
6 - Radiator/cooler
V50-
⇒ page 233
block
with fresh coolant.
11 - Coolant pump

1.4 Coolant hose schematic diagram (Passat, Passat CC)
1 - Expansion tank
❑ Check cooling system
for leaks using cooling
system tester - V.A.G
1274 B- and adapter for
cooling system tester -
V.A.G 1274/8-
2 - Intake manifold
⇒ page 343
3 - Charge air pipe with con‐
densate trap
❑ Assembly overview
⇒ page 321
5 - Gear oil cooler
❑ Only vehicles with a du‐
al clutch gearbox
6 - Engine preheating element
- Z97-
⇒ page 252
7 - Thermostat
⇒ page 210
8 - Radiator/cooler
⇒ page 266
⇒ page 212
V50-
12 - Cylinder head and cylinder block
❑ If renewed, refill system with fresh coolant.
13 - Coolant pump

1.5 Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf, Touran,
Tiguan, Golf Cabriolet)

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

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

Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet

– Pull off retaining clip -arrow- and remove coolant hose from
radiator.
Tiguan
– Detach spring-type clip and pull off coolant hose -2-.

Disregard item -1-.
Note
Please observe disposal instructions!
Filling
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost Anti-freeze Coolant ad‐ Distilled wa‐
protection to proportion ditive 4) ter 4)
-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
4) The quantity of coolant can vary depending upon vehicle equipment.
Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet

– Press connection against radiator and slide retaining clip

-arrow- into groove.
Tiguan
– Push coolant hose -2- together with spring-type clip onto con‐
nection.
Disregard item -1-.
– Depending on vehicle equipment, install noise insulation or
With cooling system charge unit - VAS 6096-
– Fill coolant circuit using cooling system charge unit -
VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
Without cooling system charge unit - VAS 6096-
– Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan - V7- cuts in.
Caution
The auxiliary heater must only be switched on when the coolant

circuit is filled, described as follows:

– Connect vehicle diagnostic, testing and information system -

VAS 5051B- as follows:
– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary/supplementary heater” and “03 - Final control diag‐
nosis” one after the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed of approx. 2,000
rpm for about 1 minute.
WARNING

– Check coolant level and top up as needed. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark and between the min. and max. marks when
the engine is cold.
1.6 Draining and filling coolant (Polo)


equipment required
Draining
WARNING


– Pull coolant hose from bottom of radiator.
Note
Observe environmental regulations for disposal.

Filling
Caution
sion.

Note
ical climates.
additives.
coolant hoses.

-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
Polo
– Connect coolant hose to bottom of radiator.
unit VAS 6096 .


Caution

– Connect vehicle diagnostic, testing and information system -

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
Auxiliary/supplementary heater” and “03 - Final control diag‐
nosis” one after the other.
- N279- . Continue to maintain engine speed of approx. 2,000
WARNING


the engine is cold.
1.7 Draining and filling coolant (Sharan)


equipment required
Draining
WARNING


– Remove engine splash guard.

– Release spring-type clip unit and pull coolant hose off -2-.
Disregard item -1-.
Note
Filling
Caution
sion.

Note
ical climates.
additives.
coolant hoses.

-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l

– Push coolant hose -2- together with spring-type clip onto con‐
nection.
Disregard item -1-.
– Install engine splash guard.
unit VAS 6096 .

Caution
Do not switch auxiliary heater on until the cooling circuit has

been filled as subsequently described.

– Connect vehicle diagnosis, testing and information system -

– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Start engine and maintain engine speed at approx. 2,000 rpm
for approx. 3 minutes.
Auxiliary heater” and “03 - Final control diagnosis” one after
the other.
- N279- . Continue to maintain engine speed at approx. 2,000
WARNING


the engine is cold.
1.8 Draining and filling coolant (Passat,

Passat CC)
Caution
sion.


equipment required
Draining
WARNING

WARNING



– Pull out retaining clip -arrow- and pull off coolant hose from
radiator.
Continued for vehicles with engine preheater heater element -

Z97-
– Loosen spring-type clips -arrows-.
– Pull off coolant hoses -2- on engine preheater heater element
- Z97- -1-.
– Allow remaining coolant to drain out.
Continued for vehicles with condensate trap

– Open spring-type clips -arrows-.
– Pull off coolant hose -1- and charge air pipe -2-.


– Open clips and pull auxiliary heater - - coolant hoses off cool‐
ant pipes -1-.
Note
Filling
Caution
sion.

Note
ical climates.
additives.
coolant hoses.

-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l

– Press connection against radiator and slide retaining clip

-arrow- into groove.
– Secure spring-type clips using hose clip pliers - VAS 6340- or
spring-type clip pliers - VAS 5024A- .
– 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).
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front, noise insulation .
unit VAS 6096 .

– Switch off heater controls.
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
Caution



– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
Auxiliary heater” and “03 - Final control diagnosis” one after
the other.
- N279- . Continue to maintain engine speed at approx. 2,000
WARNING


the engine is cold.
1.9 Checking cooling system for leaks (Polo, Touran, Golf Plus, Eos, Scirocco,
Golf, Golf Cabriolet)


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

♦ Adapter for cooling system tester - V.A.G 1274/8-
• Engine at operating temperature.
Test sequence
WARNING
Hot steam may escape when expansion tank is opened. Place

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

– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.

– Use hand pump on tester to create a pressure of about 1.0 bar.
WARNING
Risk of scalding! Before disconnecting cooling system tester -

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

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Use hand pump on cooling system tester to create a pressure
of max. 1.4 bar.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:
– Renew sealing cap.
– Increase pressure to over 1.4 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew sealing cap.
1.10 Checking cooling system for leaks (Sharan, Tiguan)


equipment required

Test sequence
WARNING


– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.

– Generate about 1.0 bar pressure using hand pump of tester.
WARNING
Risk of scalding! Before disconnecting cooling system tester -

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

1274/9- .
– Build up pressure to maximum 1.6 bar using hand pump on
cooling system tester.
– Renew cap.
– Renew cap.
1.11 Checking cooling system for leaks (Passat, Passat CC)


equipment required

Test sequence
WARNING


– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Screw connector - V.A.G 1274 B/1- into adapter for cooling
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.

– Generate about 1.0 bar pressure using hand pump of tester.
WARNING
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- it is essential that the pressure is first re‐
lieved. To do this, press pressure relief valve on cooling system
tester - V.A.G 1274 B- until pressure gauge displays value of
»0«.

1274/9- .
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Build up pressure to maximum 1.4 bar using hand pump on
cooling system tester.
– Renew cap.
– Renew cap.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - thermostat”, page 210
⇒ “2.2 Assembly overview - thermostat (Passat, Passat CC)”,
page 212
⇒ “2.3 Removing and installing coolant pump (Polo, Touran, Golf
Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)”, page 213
⇒ “2.4 Removing and installing coolant pump belt pulley (Polo,
Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)”,
page 217
⇒ “2.5 Removing and installing coolant circulation pump V50 (Po‐
lo, Touran, Golf Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabrio‐
let)”, page 222
⇒ “2.6 Removing and installing coolant pump (Sharan)”,
page 224
⇒ “2.7 Removing and installing coolant pump belt pulley (Shar‐
an)”, page 229
⇒ “2.8 Removing and installing coolant circulation pump V50
(Sharan)”, page 233
⇒ “2.9 Removing and installing coolant pump belt pulley (Passat,
Passat CC)”, page 235
⇒ “2.10 Removing and installing coolant pump (Passat, Passat
CC)”, page 241
⇒ “2.11 Removing and installing coolant circulation pump V50
(Passat, Passat CC)”, page 248
⇒ “2.12 Assembly overview - heater element for engine preheater
Z97 (Passat, Passat CC)”, page 250
⇒ “2.13 Removing and installing heater element for engine pre‐
heater Z97 (Passat, Passat CC)”, page 252
2.1 Assembly overview - thermostat

1 - Union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Plunger
❑ Do not cant when instal‐
ling
5 - Thermostat 2
❑ Starts to open at 96 °C
6 - Radiator outlet coolant -
G62-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
7 - Retaining clip
❑ Check for firm seating
9 - Seal
❑ Renew
10 - Thermostat 1
❑ Starts to open at 80 °C
11 - To expansion tank
❑ Coolant hose schematic
diagram (Golf Plus, Eos,
Scirocco, Golf, Touran,
Polo, Golf Cabriolet)
⇒ page 180
❑ Coolant hose schematic
diagram (Tiguan)
⇒ page 181
12 - Union
13 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 211) .
❑ To remove, remove supercharger ⇒ page 298 .
❑ Coolant hose schematic diagram (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Golf Cabriolet)
⇒ page 180
❑ Coolant hose schematic diagram (Tiguan) ⇒ page 181
14 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 211) .
❑ To remove, remove supercharger ⇒ page 298 .
⇒ page 180
15 - 5 Nm
16 - From bottom of radiator.
⇒ page 180
2. Coolant pump, regulation of cooling system 211

17 - To top of radiator
⇒ page 180
2.2 Assembly overview - thermostat (Passat, Passat CC)

Components on engine
1 - Coolant pump
⇒ page 241
2 - Bolt
❑ 8 Nm
❑ Qty. 3
- Z97-
⇒ page 252
4 - Bolt
❑ 10 Nm
5 - Bolt
❑ 10 Nm
❑ Qty. 3
6 - Charge air pipe with con‐
densate trap
⇒ page 321
7 - Engine
8 - Bolt
❑ 10 Nm
V50-
⇒ page 248
10 - Bolt
❑ 5 Nm
❑ Qty. 4
11 - Thermostat
❑ Assembly overview ⇒ page 210
12 - Bolt
❑ 8 Nm
❑ Qty. 5
13 - Oil cooler

2.3 Removing and installing coolant pump

(Polo, Touran, Golf Plus, Eos, Tiguan,
Scirocco, Golf, Golf Cabriolet)
Note
Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.

equipment required
♦ Torque wrench - V.A.G 1331- (not illustrated)
♦ Bit - T10451- (not shown)

Removing
– Drain coolant (Golf Plus, Eos, Scirocco, Golf, Touran, Tiguan,
– Drain coolant (Polo) ⇒ page 188 .

pressure pipe.

– Open hose clip -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3-.
Polo
– Remove engine mounting ⇒ page 66 .
– To do so, remove bolts -arrows-.



G31- -1-.
Removing poly V-belt (Tiguan) ⇒ page 78 .
Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo,
– Push securing clip at charge air cooler in direction of -arrow-

and pull hose -arrow- off.
Note
Charge air hoses with screw-type clips are also installed.
– Unscrew securing bolt for charge air pipe -arrow- and remove
charge air pipe -1- downwards.
Only vehicles with auxiliary heater
– Remove coolant hoses for auxiliary heater.

– Carefully press locking lugs on noise insulation housing for

supercharger -arrows- outwards.
– Pull off front housing with noise insulation.
Tiguan with four-wheel drive
– Remove front exhaust pipe ⇒ page 401 .
Note
The front exhaust pipe is only unbolted at the attaching points and
placed down on the subframe.
– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
– Unscrew securing bolts -arrows- for tensioning element and

remove tensioning element.
– Hold supercharger shaft with 16 mm spanner -1-.

– Remove securing bolt -2- for pulley and remove pulley and
supercharger poly V-belt -3-.

– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
Installing
Note


note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing bolts to 8 Nm.
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .
– Bolt on supercharger pulley with poly-v-belt and new securing
bolt.
Specified torques:
Caution

Assembly overview - part I, belt drive ⇒ page 71 .

Assembly overview - supercharger ⇒ page 296
Assembly overview - charge air system (Golf Plus, Eos, Scirocco,
Golf, Touran, Tiguan, Golf Cabriolet) ⇒ page 319
Assembly overview - charge air system (Polo) ⇒ page 320
Install poly V-belt (Tiguan) ⇒ page 78 .
Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet,
Touran, Polo) ⇒ page 75
Draining and filling with coolant (Golf Plus, Eos, Scirocco, Golf,
Golf Cabriolet, Touran, Tiguan) ⇒ page 184
Draining and filling with coolant (Polo) ⇒ page 188
2.4 Removing and installing coolant pump belt pulley (Polo, Touran, Golf Plus,
Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)


equipment required
♦ Bit XZN 10 - T10154-

Removing
Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo
Tiguan


– Pull retaining clip in direction of -arrow- and pull out charge air
hose -1- from charge air pipe.
Note
Charge air hoses with screw-type clips are also installed.
– Unscrew securing bolt for charge air pipe -arrow-.
– Unclip bracket -2- for electric wire to oil level and oil tempera‐
ture sender - G266- .

– Carefully press locking tabs on noise insulation housing for

– Pull off housing with noise insulation and place to one side.
rection of -arrow-.
– Detach fuel supply line -1- and line leading to activated char‐
coal filter -2- by pressing the release tabs.

pressure pipe.



Note
Charge air pressure sender - G31- with intake air temperature

sender 2 - G299- is installed on rear of charge air pipe.

G31- -1-.
– Loosen securing bolts -1- for coolant pump pulley.
WARNING
As the poly V-belt is still tensioned, the pulley securing bolts

must not yet be removed.
– Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cab‐
riolet, Touran, Polo) ⇒ page 75 .

– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing
– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Install poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cab‐
riolet, Touran, Polo) ⇒ page 75 .
Further installation is carried out in reverse order of removal.
When installing, note the following:
Specified torques:
Assembly overview - charge air system ⇒ page 319
Assembly overview - intake manifold ⇒ page 343 .

2.5 Removing and installing coolant circulation pump - V50- (Polo, Touran, Golf
Plus, Eos, Tiguan, Scirocco, Golf, Golf Cabriolet)


equipment required
♦ Hose clamps to 40 mm - 3093-
Removing
Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo

Tiguan
– Seal coolant hoses with hose clamps up to 40 mm - 3093- .
– Remove spring-type clips -arrows- and pull coolant hoses off.
– Pull connector -1- off and remove securing bolt -2-.
– Remove coolant circulation pump - V50- -3-.
Installing
note the following:
Specified torque for securing bolt: 10 Nm.
– Check coolant level; replenish as necessary (Golf Plus, Eos,
Scirocco, Golf, Golf Cabriolet, Touran, Tiguan) ⇒ page 184 .
– Check coolant level; replenish as necessary (Polo)
⇒ page 188 .
2.6 Removing and installing coolant pump

(Sharan)
Note



equipment required
Removing
Note



pressure pipe.



G31- -1-.
Remove poly V-belt ⇒ page 75 .



– Carefully press locking lugs on noise insulation housing for

– Unscrew the securing bolt for charge air pipe -arrows- and re‐
move charge air pipe -1- downwards.


T10241- .

Disregard item -4-.


– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
Installing
Note


note the following:
N421- .
bolt.
Specified torques:
Assembly overview - supercharger ⇒ page 296 .
Assembly overview - charge air system ⇒ page 319 .
2.7 Removing and installing coolant pump belt pulley (Sharan)


equipment required
♦ Bit XZN 10 - T10154-

Removing
– Pull retaining clip in direction of -arrow- and pull charge air
hose -1- out of charge air pipe.

– Unscrew the securing bolt for charge air pipe -arrow-.
rection of -arrow-.
Note



pressure pipe.
– Unscrew hose clip -1- at charge air pipe.

– Open hose clip -2- unit and pull hose off.
– Unscrew securing bolt for charge air pipe -3- and pull connec‐
tor off charge air pressure sender - G31- with intake air tem‐
perature sender 2 - G299- .
– Remove holder -4-.

G31- -1-.
Note
Charge air pressure sender - G31- with intake air temperature

sender 2 - G299- is installed on rear of charge air pipe.
– Loosen securing bolts -1- for coolant pump pulley.
WARNING


– Unscrew securing bolts -1- and pull pulley from coolant pump.
Installing
– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Tighten securing bolt to 24 Nm.
When installing, note the following:
Specified torques:

2.8 Removing and installing coolant circulation pump - V50- (Sharan)


equipment required
Removing
– Seal coolant hoses with hose clamps up to 40 mm - 3093- .

– Remove spring-type clips -arrow- and pull coolant hoses off.

– Pull connector -1- off and remove securing bolt -2-.
– Remove continued coolant circulation pump - V50- .
Installing
note the following:
Specified torque for securing bolt: 10 Nm.
– Check coolant level; replenish as necessary (Sharan)
⇒ page 192 .
2.9 Removing and installing coolant pump belt pulley (Passat, Passat CC)

equipment required
♦ Bit XZN 10 - T10154-


Removing
WARNING


Note
Charge air hoses with screw-type clips are also installed

⇒ page 334 .


– Clamp off coolant hoses -1- using hose clamps, up to 40 mm in
diameter - 3093- .
– Pull off coolant hoses -1- on charge air pipe -2-.
Vehicles with engine preheater heater element - Z97-



– Seal coolant hoses to auxiliary heater - Z- with hose clamps
up to 40 mm - 3093- .
– Pull coolant hoses for auxiliary heater - Z- off coolant pipes
-1-.

Note
Housing with noise insulation remains in vehicle.
of -arrow-.


pressure pipe.



G31- -1-.

– Loosen securing bolts -1- for coolant pump belt pulley.
WARNING

– Unscrew securing bolts -1- and pull off belt pulley from coolant
pump.
Installing
following:
– Position belt pulley on coolant pump and tighten securing bolts

-1- by hand.
– Tighten securing bolts -1-.
Caution

Note


twisted.
ed and engaged.
– Check coolant level and top up if necessary ⇒ page 197 .
– Push down engine cover panel at points -1- in direction of

-arrow- until engine cover panel engages.
Specified torque
Components Specified torque
Securing bolts for charge air pipe 10 Nm
Screw-type hose clips on charge air pipes 5.5 Nm
Belt pulley to coolant pump 20 Nm
2.10 Removing and installing coolant pump (Passat, Passat CC)
Note
Coolant pump seal is bonded in position. If the seal is damaged, the coolant pump must be renewed.


equipment required

Removing
Note
Charge air hoses with screw-type clips are also installed

⇒ page 334 .
– Unclip bracket -2- for electric wire to oil level and oil tempera‐
ture sender - G266- .


Vehicles with engine preheater heater element - Z97-


– Pull coolant hoses for auxiliary heater - Z- off coolant pipes
-1-.

Note
Housing with noise insulation remains in vehicle.

of -arrow-.

pressure pipe.




G31- -1-.

T10241- .
– Use the locking pin - T10060 A- to lock the tensioning element
in place.


– Hold supercharger shaft with AF 16 spanner -1-.

– Remove securing bolt -2- for belt pulley and remove belt pulley
and supercharger poly V-belt -3-.
– Loosen bolts -arrows- of coolant pump using socket -

T10451- .
Installing
following:
Note


– Tighten bolts.
N421- .
bolt.
Caution

Note


twisted.
ed and engaged.
Assembly overview - supercharger ⇒ page 296
Fill with coolant ⇒ page 197
Specified torque
Coolant pump to engine 8 Nm
Belt pulley to coolant pump 24 Nm
Belt pulley for supercharger 40 Nm + 90°
Securing bolts for charge air pipe 5 Nm
Screw-type hose clips on charge pressure pipes 5.5 Nm
Belt drive ⇒ page 71
Charge air system ⇒ page 321
Compressor ⇒ page 296
2.11 Removing and installing coolant circulation pump - V50- (Passat, Passat
CC)


equipment required

Removing
WARNING


– Seal coolant hoses for coolant circulation pump - V50- using
hose clips up to 40 mm - 3093- .
– Release spring-type clips -arrows- and pull off coolant hoses.
– Pull off connector -1- and unscrew securing bolt -2-.
– Remove coolant circulation pump - V50- -3-.
Installing
following:
Specified torque
Securing bolt 10 Nm
2.12 Assembly overview - heater element for engine preheater - Z97- (Passat,
Passat CC)

1 - Bolt
❑ 10 Nm
2 - Bracket
❑ Note installation posi‐
tion ⇒ page 252
3 - Clip
4 - Connection for coolant hose
❑ To engine
❑ Connection diagram for
coolant hoses
⇒ page 183
5 - Connection for coolant hose
❑ To thermostat housing.
coolant hoses
⇒ page 183
- Z97-
⇒ page 252
7 - Bracket
❑ Comprises upper and
lower part
❑ For engaging wiring har‐
ness in radiator grille
8 - Connecting cable
❑ 220 V
9 - Air intake grille
❑ Right side

2.13 Removing and installing heater element for engine preheater - Z97- (Pas‐
sat, Passat CC)

equipment required

Removing
WARNING


– Unclip locking mechanism -arrow-.
– Pull off wiring -1- on engine preheating element - Z97- -2-.
– Clamp off coolant hoses -2- using hose clamps, up to 40 mm in

diameter - 3093- .
– Loosen spring-type clips -arrows-.
– Pull off coolant hoses -2- from engine preheater heater ele‐
ment - Z97- -1-.
– Unscrew bolt -arrow A- and remove engine preheater heater

element - Z97- -1- with bracket.
– Open clip, and detach engine preheating element - Z97- from
bracket.
Installing
following:

Installation position of engine preheater heater element - Z97-

Observe anti-twist device -arrow-
– Fit bracket of engine preheater heater element - Z97- -1- with

lug in guide -arrow B-.
– Tighten bolt -arrow A-.
Specified torque
Bracket to engine 10 Nm

3 Radiator, radiator fan

⇒ “3.2 Assembly overview - parts of cooling system, body side
(Tiguan)”, page 257
⇒ “3.3 Assembly overview - radiator/radiator fan (Polo)”,
page 259
⇒ “3.4 Assembly overview - radiator/radiator fan (Sharan)”, page
260
⇒ “3.5 Assembly overview - radiator/radiator fan (Passat, Passat
CC)”, page 261
⇒ “3.6 Removing and installing radiator fan V7 and radiator fan 2
V177 (Eos, Golf Plus, Scirocco, Golf, Touran, Golf Cabriolet)”,
page 262
⇒ “3.7 Removing and installing radiator fan V7 and radiator fan 2
V177 (Polo)”, page 263
⇒ “3.8 Removing and installing radiator, radiator fan V7 and ra‐
diator fan 2 V177 (Sharan)”, page 264
⇒ “3.9 Removing and installing radiator (Passat, Passat CC)”,
page 266
⇒ “3.10 Removing and installing fan cowling (Passat, Passat
CC)”, page 269
⇒ “3.11 Removing and installing radiator fan V7 and radiator fan
2 V177 (Passat, Passat CC)”, page 270
⇒ “3.12 Removing and installing radiator (Golf Plus, Eos, Sciroc‐
co, Golf, Touran, Golf Cabriolet)”, page 271
⇒ “3.13 Removing and installing radiator and radiator fan V7 (Ti‐
guan)”, page 272
⇒ “3.14 Removing and installing radiator with charge air cooler
(Polo)”, page 274
3.1 Assembly overview - radiator/radiator fan (Eos, Golf Plus, Scirocco, Golf,
Touran, Golf Cabriolet)
3. Radiator, radiator fan 255

1 - Radiator/cooler
⇒ page 271
❑ After renewing, renew
entire coolant.
2 - O-ring
3 - Upper coolant hose
❑ To connection on cylin‐
der head.
coolant hoses
⇒ page 180
4 - Expansion tank
V.A.G 1274/8-
5 - Connector
6 - Cap
❑ Check using cooling
V.A.G 1274/9-
❑ The pressure relief
valve must open at a
pressure of 1.4…1.6 bar
7 - 5 Nm
8 - Plastic inserts
❑ For securing bolts.
9 - Bracket
10 - Cowling
11 - 5 Nm
12 - Radiator fan 2 - V177-
13 - Connector
14 - Radiator fan - V7-
❑ With radiator fan control unit - J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
19 - 5 Nm

3.2 Assembly overview - parts of cooling system, body side (Tiguan)
1 - Radiator/cooler
⇒ page 272
entire coolant.
2 - O-ring
3 - Union
❑ To remove, pull out re‐
taining clip.
4 - Spring-type clip
❑ Remove and install with
hose clip pliers - VAS
6340- .
5 - Coolant hose
coolant hoses
⇒ page 180
❑ To connection on cylin‐
der head.
coolant hoses
⇒ page 181
7 - Expansion tank
V.A.G 1274/8-
8 - Connector
9 - Cap
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ The pressure relief valve must open at a pressure of 1.4…1.6 bar
10 - 5 Nm
11 - Plastic inserts
12 - Bracket
13 - 5 Nm
14 - Cowling with radiator fan - V7-
Note
The radiator fan - V7- and the cowl‐

ing may only be renewed complete.

WARNING
Heat shields must be in‐
stalled to prevent dam‐
age to radiator fan due to
heat radiated by exhaust
system.
❑ Specified torque for heat shields: 3 Nm.

15 - Bracket
❑ For connector.
16 - Connector
17 - Retaining clip
❑ Connection diagram for coolant hoses ⇒ page 180
19 - Hose guide
22 - Union
❑ To remove, pull out retaining clip.

3.3 Assembly overview - radiator/radiator fan (Polo)
1 - Radiator/cooler
⇒ page 274
entire coolant
⇒ page 188
3 - Coolant hose
❑ To expansion tank
5 - Cap
V.A.G 1274/9-
❑ The pressure relief
valve must open at a
pressure of 1.4…1.6 bar
6 - Expansion tank
V.A.G 1274/8-
7 - 5 Nm
8 - Connector
9 - Plastic inserts
10 - Bracket
11 - Cowling
12 - 5 Nm
14 - Connector
15 - Bracket
❑ For connector.
17 - Charge air cooler

3.4 Assembly overview - radiator/radiator fan (Sharan)
1 - Coolant hose
❑ To top of expansion tank
coolant hoses
⇒ page 182
2 - Coolant hose
❑ To bottom of expansion
tank
coolant hoses
⇒ page 182
3 - Clip
4 - Connector
5 - Cap
V.A.G 1274/9-
❑ Pressure relief valve
must open at between
1.4 and 1.6 bar
6 - 5 Nm
7 - Expansion tank
V.A.G 1274/8-
8 - Coolant hose
coolant hoses
⇒ page 182
9 - Radiator/cooler
10 - Cowling
❑ with radiator fan - V7- and radiator fan 2 - V177-
11 - 5 Nm
12 - Connector

3.5 Assembly overview - radiator/radiator fan (Passat, Passat CC)
1 - Coolant hose
❑ To bottom of expansion
tank
coolant hoses
⇒ page 183
2 - Coolant hose
❑ To top of expansion tank
coolant hoses
⇒ page 183
3 - Clip
❑ To fit spring-type clips,
6340- or spring-type clip
pliers - VAS 5024A- are
recommended
4 - Connector
❑ For coolant shortage in‐
dicator sender - G32- .
5 - Cap
V.A.G 1274/9-
❑ Pressure relief valve
must open at between
1.4 and 1.6 bar
6 - Bolt
❑ 5 Nm
❑ Qty. 2
7 - Expansion tank
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
system tester - V.A.G 1274/8-
8 - Cowling
❑ with radiator fan - V7- and radiator fan 2 - V177-
9 - Bolt
❑ 5 Nm
❑ Qty. 4

14 - Nut
❑ 10 Nm
❑ Qty. 6
15 - Radiator/cooler
3.6 Removing and installing radiator fan -

V7- and radiator fan 2 - V177- (Eos, Golf
Plus, Scirocco, Golf, Touran, Golf Cab‐
riolet)
Removing radiator fan
– Remove engine cover.
– Remove upper securing bolts of cowling -arrows-.
Rep. gr. 50 ; Body - front; Noise insulation .
– Separate connector -1- and unscrew lower cowling securing

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

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
note the following:
Specified torques:
Component Nm
Radiator fan to cowling 10
Cowling to radiator 5


V7- and radiator fan 2 - V177- (Polo)
Removing
– Disconnect electrical connector -arrow-.
– Pull connector -arrow- from radiator outlet coolant temperature

sender - G83- .
– Pull off intake hose -1-.

– Unscrew securing bolts -arrows- and remove intake cowl.
– Press both radiator latches in -direction of arrow-.

– Carefully remove cowling -1- downwards together with radia‐
tor fans.

– Disconnect connector -1-.

Depending on which radiator fan is to be removed.
– Unclip line from line guide and unscrew securing nuts
-arrows-.
Installing
note the following:
Specified torques
Component Nm
Radiator fan to air scoop 5
3.8 Removing and installing radiator, radiator fan - V7- and radiator fan 2 -
V177- (Sharan)

equipment required

Removing
– Also remove second hose from charge air cooler.

– Drain coolant. Pull off hose -2-.
– Release retaining clip and pull connection -arrow- off radiator.

– Pull the connection from bottom of radiator.
– Unclip coolant hose from cowling.
sition .
– Unscrew securing bolts -arrows- and remove cowling upwards

together with the radiator fans.

– Disconnect electrical connector -1- and lay lines aside.

– Unscrew the securing bolt -arrow-.
– Unscrew bolts -arrows- and remove radiator downwards.
Note
To prevent damage to condenser or to refrigerant lines and ho‐

ses, ensure that lines and hoses are not stretched, kinked or bent.
– Unbolt retaining clamps for refrigerant lines.

– Unbolt condenser from radiator and secure to lock carrier.
Installing
note the following:
Filling with new coolant ⇒ page 192 .
– Electrical connections and routing ⇒ Current flow diagrams,
Specified torques:
Component Nm
Radiator fan to cowling 10
Radiator to charge air cooler 5
3.9 Removing and installing radiator (Passat, Passat CC)


equipment required
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
Removing
or skid plate .


side.

– Loosen screw-type hose clip -arrow-.
– Loosen screw-type hose clip on right-hand side as well and
pull off charge air hose.

– Pull off coolant hose -1- from top of radiator.



– Remove radiator -1- downwards.
Installing
following:
Caution

Note

twisted.
ed and engaged.
– Fill with coolant ⇒ page 197 .
Specified torque
Component Nm
3.10 Removing and installing fan cowling

(Passat, Passat CC)
Removing
or skid plate .


– Remove cowling with radiator fan - V7- and radiator fan 2 -
V177- downwards.
Installing
the following:
Specified torque
Cowling to radiator 5 Nm

V7- and radiator fan 2 - V177- (Passat,
Passat CC)
Removing radiator fan
or skid plate .
– Uncover cables -1-.

Installing radiator fan
following:
Specified torque
Radiator fan to cowling 10 Nm

3.12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)

equipment required
Removing
– Pull coolant hoses off radiator.
– Remove cowling together with radiator fans downwards
⇒ page 262 .
– Remove radiator securing bolts and remove radiator with fan
downwards.

Note
To prevent damage to condenser or to refrigerant lines and ho‐

ses, ensure that lines and hoses are not stretched, kinked or bent.
– Unbolt retaining clamps for refrigerant lines.

– Unbolt condenser from radiator and secure to lock carrier.
Installing
note the following:
3.13 Removing and installing radiator and radiator fan - V7- (Tiguan)

equipment required

Removing
– Remove bracket -1- by unscrewing securing bolts -arrows-.



– Also pull off connection at bottom of radiator.


together with radiator fan - V7- .
Note
♦ The radiator fan - V7- and the cowling may only be renewed
complete.
♦ To remove and install radiator, lock carrier only has to be
moved to service position.

sition .
– Remove securing bolt -arrow-.

Installing
note the following:
Specified torques:
Component Nm
3.14 Removing and installing radiator with

charge air cooler (Polo)
Caution

Note
♦ Radiator and charge air cooler are separate components.

♦ Radiator is mounted onto charge air cooler.
♦ Radiator and charge air cooler are removed and installed to‐
gether.

Assembly overview - parts of cooling system, body side

⇒ page 259 .
Removing
– Pull upper coolant hose off radiator.
– Removing cowling with both radiator fans ⇒ page 263 .
– Remove both charge air hoses.
– Disconnect electrical connector -arrow-.
– Pull connector -arrow- from radiator outlet coolant temperature

sender - G83- .
sition .
– Remove securing bolts -arrows-.

– Lift radiator out of lower mountings and press it back slightly.
– Remove side radiator mounting.
– Unscrew securing bolt on side for AC compressor lines.

– Remove securing bolts of condenser -arrows-.

– Secure condenser to lock carrier using cable ties.
– Remove radiator and charge air cooler downwards.
– Pull radiator -1- in -direction of arrow- out of lateral charge air

cooler -2- mounting brackets.
Installing
note the following:
Filling with new coolant
⇒ “1.6 Draining and filling coolant (Polo)”, page 188 .
Specified torques
Component Nm
Radiator mounting to lock carrier 5
Bracket for air conditioner compressor lines to 5
radiator
Radiator to condenser 5

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

production standard.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The seal and sealing
surface must be oiled lightly only for plug-in connectors
⇒ page 322 .
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ It is recommended that spring-type clips should be installed
using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed and do not rev up immediately. This ensures that
the turbocharger is fully primed with oil.
⇒ “1.1 Assembly overview - turbocharger”, page 277

⇒ “1.2 Removing and installing turbocharger”, page 281
⇒ “1.3 Checking vacuum unit for turbocharger”, page 286
⇒ “1.4 Removing and installing vacuum unit for turbocharger”,
page 288
⇒ “1.5 Adjusting vacuum unit for turbocharger”, page 290
1.1 Assembly overview - turbocharger
1. Exhaust turbocharger 277

Part I
278 Rep. gr.21 - Turbocharging/supercharging

1 - Charge pressure control

solenoid valve - N75-
2 - 10 Nm
3 - 7 Nm
4 - Turbocharger air recircula‐
tion valve - N249-
❑ To remove, pressure
pipe must be removed
⇒ page 283 .
5 - O-ring
⇒ page 281
❑ Checking turbocharger
vacuum unit
⇒ page 286 .
vacuum unit for turbo‐
charger ⇒ page 288 .
❑ Adjusting vacuum unit
for turbocharger
⇒ page 290 .
7 - Connection hose
8 - Connection hose
Part II

1 - 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew
❑ Specified torque for cat‐
alytic converter studs:
20 Nm
⇒ page 281
❑ Checking turbocharger
vacuum unit
⇒ page 286 .
vacuum unit for turbo‐
charger ⇒ page 288 .
❑ Adjusting vacuum unit
for turbocharger
⇒ page 290 .
5 - Seal
❑ Renew
6 - Bracket
Note
♦ Retainer is discontinued.
♦ The retainer is not reinstalled in
cases of repair.
7 - Bracket
Note
♦ The retainer is not reinstalled in
cases of repair.
8 - 25 Nm
❑ Renew studs and fastening nuts.
Screw the studs into cylinder head until they project only 25 mm.
Coat studs with high-temperature paste.
Observe tightening sequence: items -A- to -I-.
9 - Coolant pipe
10 - Seal
❑ Renew
11 - 8 Nm
12 - Oil return pipe
❑ To remove, catalytic converter needs to be removed ⇒ page 415 .
13 - Seal
❑ Renew

14 - Banjo bolt, 20 Nm
❑ Secured to valve timing housing.
15 - Oil supply pipe
Caution
Oil supply line must be
renewed when installing
a new turbocharger.
16 - Banjo bolt, 30 Nm
1.2 Removing and installing turbocharger


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

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


rection of -arrow-.


cooling system.
– Drain coolant (Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet,
Touran, Tiguan) ⇒ page 184 .
– Remove radiator fan - V7- together with cowling ⇒ page 255 .
Note
– Pull off connecting hoses -1- and coolant hoses -3-.

– Unscrew bracket -2- and securing nuts -4- from turbocharger.
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe

.
Passat, Passat CC
– Remove cowling ⇒ page 269 .
– Remove catalytic converter ⇒ page 424 .


G130- and remove.
– Unbolt exhaust pipe to rear silencer -arrows-.
Note
In the Polo, the catalytic converter is removed together with the

front exhaust pipe.

to rear.
– Also pull out exhaust pipe together with flexible joint.
– Remove catalytic converter together with charge air pipe
downwards.
Removing poly V-belt (Tiguan) ⇒ page 78 .
Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabrio‐
let, Touran, Polo, Sharan, Passat, Passat CC) ⇒ page 75 .

– Unscrew securing bolts for tensioning element -arrows- and

remove it.
– Remove upper alternator bolt and swing alternator out for‐
wards.
– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
bocharger.
– Pull oil return pipe downwards.

– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts of oil supply pipe -arrows- from turbo‐
charger and valve timing housing.
– Remove oil supply pipe.

– Unscrew all securing nuts from exhaust manifold -1-.
– Pull exhaust manifold out upwards with turbocharger.
Note
The turbocharger can only be renewed together with the exhaust

manifold.
Installing
Caution
Oil supply line must be renewed when installing a new turbo‐

charger.

note the following:

♦ Renew studs and fastening nuts.

♦ Screw the studs into cylinder head until they project only
25 mm.
♦ Coat studs with high-temperature paste.
♦ Observe tightening sequence and specified torques: items
-A- to -I- ⇒ page 277 .
♦ Renew seals, gaskets and self-locking nuts.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
free of oil and grease before assembly.
♦ Install exhaust system and align it free of stress.
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.
Fitting hose connections with plug-in connectors ⇒ page 322
Specified torques:
Caution

Assembly overview - turbocharger ⇒ page 277 .

Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf
Cabriolet, Touran, Scirocco, Tiguan, Sharan) ⇒ page 319
Assembly overview - charge air system (Passat, Passat CC)
⇒ page 321
Assembly overview - catalytic converter and add-on parts
⇒ page 395
Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing alternator .

1.3 Checking vacuum unit for turbocharger


♦ Hand operated vacuum pump - VAS 6213-
– Check retaining clip -1- is seated correctly on vacuum unit

linkage.
Securing nut -2- must be locked with sealing paint.
– Pull hose -arrow- off vacuum unit.
– Fit hose -2- onto vacuum unit connection.

– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
stop in direction of -arrow-.

– Operate hand vacuum pump - VAS 6213- until a pressure of

700 mbar is displayed on pressure gauge.
Linkage of vacuum unit -1- must move in direction of -arrow-.
If pressure of 700 mbar is displayed:
Vacuum unit is OK.
If pressure drops abruptly:
– Renew vacuum unit ⇒ page 281 .
1.4 Removing and installing vacuum unit for

turbocharger
Removing
– Release vacuum hose on vacuum reservoir -arrow- and pull it
off.
rection of -arrow-.

– Pull hose -1- from pressure pipe and unscrew securing bolts
-2- for pressure pipe.
– Remove pressure pipe.
– Pull hose -arrow- from vacuum unit.

– Remove sealing paint from securing nut -2-.
– Pull off retaining clip -1- and loosen securing nut -2- on vacuum
unit linkage.
– Unscrew knurled nut from vacuum unit stud.
– Unscrew securing bolts -arrows- for vacuum unit and remove

vacuum unit from turbocharger.
Installing
note the following:
♦ Linkage must be adjusted after installing vacuum unit
⇒ page 290 .
♦ Specified torque for vacuum unit to turbocharger: 10 Nm

1.5 Adjusting vacuum unit for turbocharger
Note
The vacuum unit must be adjusted only if the linkage has been
loosened.

equipment required
♦ Pressure regulating valve - VAS 6342-

♦ Dial gauge set, 4-part - VAS 6341-
♦ Hand operated vacuum pump - VAS 6213-
♦ Turbocharger tester - V.A.G 1397A-
♦ Dial gauge extension, 30 mm - VAS 6341/3- (not shown)
♦ Flat pickup - VAS 6341/4- (not shown)

Procedure
rection of -arrow-.

cooling system.
– Now drain coolant.
Note
– Pull off connecting hoses -1- and coolant hoses -3-.

– Remove bolts and securing nuts -4- from turbocharger.
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe.



G130- and remove.
– Remove catalytic converter downwards.
Note

front exhaust pipe.
– Pull hose -arrow- from vacuum unit on turbocharger.

Checking vacuum unit adjustment ⇒ page 286 .
Continuation if the vacuum unit has been renewed or the linkage
loosened
– Remove sealing paint from lock nut -2-.
– Pull off retaining clip -1- and loosen lock nut -2- on vacuum
unit linkage.
– Pre-adjust bypass flap -2- on vacuum unit linkage -1- via

knurled screw, so that bypass flap can just be turned by hand.
– Turn knurled nut -1- 2 turns further.
– Tighten lock nut hand-tight.

– Connect hand vacuum pump - VAS 6213- , turbocharger tester

- V.A.G 1397A- to connection -II- and pressure control valve -
VAS 6342- as shown in illustration.
– Close pressure control valve - VAS 6342- at lever -2-.
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
pressure gauge in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position -II-.

– Secure universal dial gauge bracket - VW 387- to turbocharg‐

er.
Note
The dial gauge linkage and the vacuum unit linkage must align.
– Secure dial gauge - VAS 6341/1- with dial gauge extension,

30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐
versal dial gauge bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Operate hand vacuum pump - VAS 6213- until a pressure of
800 mbar is displayed on turbocharger tester - V.A.G 1397A- .
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 0 mbar.
– Repeat this procedure approx. 3-5 times.
Note
This procedure is intended to prevent the vacuum unit bypass flap

or linkage from jamming.
Note
The values in mm refer to the read value (includes 1 mm preten‐

sion).

pressure reading drops to 0 mbar.
– Set dial gauge - VAS 6341/1- to 0.
Note
♦ The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between
measurements.
♦ Do not knock against linkage throughout the entire measure‐
ment procedure.
– Operate hand vacuum pump - VAS 6213- until turbocharger

tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 800 +/- 5 mbar.
pressure reading drops to 500 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5.5 +/- 0.25 mm.

– Correct setting if the result (average) is not 5.5 +/- 0.25 mm,
tighten lock nut hand-tight and repeat measurement.
– If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock
nut to 9 Nm and secure with sealing paint.
– Secure retaining clip to vacuum unit linkage.
note the following:

♦ If renewed, place seal in groove of charge air hose. Ensure
seal is correctly seated in groove.
♦ Lightly moisten seal with engine oil.
♦ Bring retaining clip to release position -arrow-.
Caution

Assembly overview - turbocharger ⇒ page 277 .

Removing and installing parts of exhaust system ⇒ page 395

2 Compressor
⇒ “2.1 Assembly overview - supercharger”, page 296
⇒ “2.2 Removing and installing supercharger”, page 298
⇒ “2.3 Removing and installing supercharger (Tiguan with four-
wheel drive)”, page 306
⇒ “2.4 Removing and installing drive unit seal for supercharger”,
page 314
2.1 Assembly overview - supercharger
1 - Housing with noise insula‐

tion
❑ For noise insulation.
2 - Noise insulation
❑ For intake air.
3 - Intake hose
❑ Secure with spring-type
clips
4 - 7 Nm
❑ Self-tapping bolt
❑ Securing bolt must only
be tightened with a nut
runner if nut runner
speed is max. 500 rpm
and a max. specified tor‐
que of 7 Nm is set.
5 - 7 Nm
6 - 7 Nm
❑ Securing bolt must only
be tightened with a nut
runner if nut runner
speed is max. 500 rpm
and a max. specified tor‐
que of 7 Nm is set.
7 - O-ring
❑ Renew
8 - Pressure pipe
10 - Housing
❑ For noise insulation.
❑ For charge air.
❑ With seal
❑ Renew seal between supercharger and noise insulation.
12 - Belt pulley

13 - 8 Nm
14 - Coolant pump with magnetic clutch for supercharger - N421-
15 - Poly V-belt
Caution
ment.
16 - 23 Nm
❑ For supercharger poly V-belt.
❑ Relieve tension using 16 mm open-end spanner - T10241- .
❑ Lock with locking pin - T10060 A- .
18 - 40 Nm + 1/4 turn (90°) further
❑ To loosen and tighten securing bolt, counterhold supercharger shaft with spanner.
❑ Renew
19 - Compressor
❑ Removing and installing (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC)
⇒ page 298
❑ Removing and installing (Tiguan with four-wheel drive) ⇒ page 306 .
❑ Removing and installing drive unit seal for supercharger ⇒ page 314
❑ Repair kit for supercharger ⇒ Electronic parts catalogue (ETKA)
20 - 25 Nm
2. Compressor 297
2.2 Removing and installing supercharger

equipment required
♦ Pliers for spring-type clips - VAS 5024A-

♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
♦ Guide pin - T10341-
Removing
rection of -arrow-.

– Detach spring-type clip from intake hose -arrow-.

pressure pipe.

2. Compressor 299


G31- -1-.
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
Remove poly V-belt (Golf Plus, Eos, Scirocco, Golf, Golf Cabrio‐
let, Touran, Polo, Sharan, Passat, Passat CC) ⇒ page 75
drive shafts .
Passat, Passat CC
Golf Plus, Eos, Scirocco, Golf, Golf Cabriolet, Touran, Polo, Shar‐
an
– Unbolt exhaust pipe to front silencer -arrows-.
Note

front exhaust pipe.


to rear.
– Also pull out exhaust pipe together with flexible joint.


– Clamp off coolant hoses -1- with hose clips up to 40 mm -
3093- .

2. Compressor 301
– Remove securing bolt -arrow- from charge air pipe -1-.
– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing

-arrows- outwards.

T10241- .


– Unscrew securing bolts -1- for supercharger and remove su‐

percharger together with intake noise insulation.
Removing noise insulation for charge air:
– Pull noise insulation for charge air -2- together with pressure
pipe in direction of -arrow-.
Installing
Note
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 296) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).
2. Compressor 303
– Push noise insulation for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.
– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .
– Tighten lower securing bolts hand-tight.
– Tighten securing bolts -1- evenly in diagonal sequence.
– Install supercharger belt pulley with poly V-belt positioned
-3-.
Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
– Install tensioner.

– Tighten bolts -arrows- to 23 Nm.
– Hold tensioning element using 16 mm open-end spanner -

T10241- and pull out locking pin - T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
– Press housing together with noise insulation against super‐

charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
2. Compressor 305

Installing hose connections with plug-in connectors
⇒ page 322 .
Specified torques:
Caution


⇒ page 395

– Fit vacuum hose onto connection -arrow-.
2.3 Removing and installing supercharger (Tiguan with four-wheel drive)


equipment required

Removing
– Pull vacuum hose off engine cover panel.
rection of -arrow-.
2. Compressor 307
– Detach spring-type clip from intake hose -arrow-.

pressure pipe.




G31- -1-.
Remove poly V-belt (Tiguan) ⇒ page 78 .
drive shafts .

2. Compressor 309

– Remove bevel box ⇒ 6-speed manual gearbox 0A6; Rep. gr.
34 ; Removing and installing bevel box .


– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing
-arrows- outwards.

– Slacken supercharger poly V-belt by swinging tensioning ele‐

ment in direction of -arrow- with 16 mm spanner.

2. Compressor 311
– Unscrew securing bolts -1- for supercharger and remove su‐

percharger together with intake silencer.
Removing intake silencer for charge air:
– Pull intake silencer for charge air -2- together with pressure
pipe in direction of -arrow-.
Installing
Note
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 296) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).
– Push noise insulation for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.

– Turn guide pins - T10341- hand-tight to stop in both lower

threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
groove.
– Push supercharger together with intake silencer onto guide
pins - T10341- and tighten upper securing bolts hand-tight.
– Remove guide pins - T10341- .
– Tighten lower securing bolts hand-tight.
– Tighten securing bolts evenly and diagonally.
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
– Press housing together with noise insulation against super‐

charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
2. Compressor 313
♦ Renew securing bolt for supercharger pulley. Specified torque

40 Nm + 1/4 turn (90°) further.
Fitting hose connections with plug-in connectors ⇒ page 322
Specified torques:
Assembly overview - charge air system (Eos, Golf Plus, Golf, Golf
Cabriolet, Touran, Scirocco, Tiguan, Sharan) ⇒ page 319
⇒ page 417

2.4 Removing and installing drive unit seal

for supercharger
♦ Gearbox support - T10108-
♦ Extractor hook - T20143-
♦ Repair kit for supercharger ⇒ Electronic parts catalogue (ET‐
KA)
Note
All components in the repair kit must be used!
Removing
– Remove supercharger ⇒ page 296

– Secure compressor on the gearbox support - T10108- with 2

bolts-arrow-.
– Pry off the circlip -1- with a slot-head screwdriver -2-.
– Pull out the seal -1- with the puller hooks - T20143/1- .
Installing
– Put together assembly cone -T10208/5- and assembly sleeve

-T10208/4- .
– Slide the new seal -1- onto the assembly sleeve in the
-arrow direction- -T10208/5- -T10208/4- via the assembly
cone.
2. Compressor 315
– Pull down the assembly cone - T10208/5- from the assembly

sleeve in the -arrow direction- -T10208/4- .
– Slide the assembly sleeve - T10208/4- onto the compressor

shaft.
– Using the thrust piece - T10208/2- , press in the seal via the
assembly sleeve - T10208/4- up to the stop.
– Press in the new circlip -1- up to the stop also using the as‐
sembly tool - T10208/2- .
Changing the compressor fluid

– Undo the securing bolts for the drive unit according to the
specified sequence -A- to -H-.
– Turn the gearbox support - T10108- until the shaft points to
the floor.
– Unscrew the securing bolts and remove the drive unit -1-.
– Drain compressor oil completely from drive unit.
– Collect the escaping fluid in a suitable container.
– Turn the gearbox support - T10108- until the pair of gears point
upwards.
– Remove sealant residues from compressor and drive unit with
a rotating brush, e.g. a hand drill with a plastic brush (wear eye
protection).
– Carefully clean sealing surfaces. They must be free of oil and
grease.
– Dirt and sealant residues must not be allowed to enter the
space.
Caution
Add only the oil specified in repair set ⇒ Electronic parts cata‐
logue (ETKA) .
– Fill the space -arrow- with new oil (44 ml) from the repair set.
Note
Sealant must not be applied too thickly, otherwise excess sealant

may enter the space and cause damage.
Do not apply sealant until directly before the drive unit is fitted.
– Apply sealant to the sealing surface on the compressor.
Bead of sealant must be 2 to 3 mm thick and must run along inside

edge in area of bolt holes.
– Tighten the new securing bolts for the drive unit to “12 Nm”
according to the specified sequence -A- to -H-.
– Install supercharger ⇒ page 296
2. Compressor 317
3 Charge air system
Caution

Note
♦ It is recommended that spring-type clips should be installed

using spring-type clip pliers - VAS 5024A- or hose clamp pliers
- VAS 6340- .
free of oil and grease before assembly. The seal and sealing
surface must be oiled lightly only for plug-in connectors
⇒ page 322 .
♦ Charge air system must be free of leaks.
⇒ “3.1 Assembly overview - charge air system (Eos, Golf Plus,

Golf, Touran, Scirocco, Tiguan, Sharan, Golf Cabriolet)”,
page 319
⇒ “3.2 Assembly overview - charge air system (Polo)”,
page 320
⇒ “3.3 Assembly overview - charge air system (Passat, Passat
CC)”, page 321
Note
In the Polo, the charge air cooler is removed and installed to‐
gether with the radiator ⇒ page 274 .
⇒ “4.2 Actuator for structure-borne sound R214 and control unit

for structure-borne sound J869 (Polo, left-hand drive)”,
page 364
⇒ “3.4 Fitting hose connections with plug-in connectors”,
page 322
⇒ “3.5 Checking charge air system for leaks”, page 323
⇒ “3.6 Removing and installing charge air cooler (Eos, Golf Plus,
Golf, Golf Cabriolet, Touran)”, page 326
⇒ “3.7 Removing and installing charge air cooler, Sharan”,
page 328
⇒ “3.8 Removing and installing charge air cooler (Scirocco)”, page
330
⇒ “3.9 Removing and installing charge air cooler, Tiguan”,
page 332
⇒ “3.10 Removing and installing charge air cooler (Passat, Passat
CC)”, page 334

3.1 Assembly overview - charge air system

(Eos, Golf Plus, Golf, Touran, Scirocco,
Tiguan, Sharan, Golf Cabriolet)
Caution


(Eos, Golf Plus, Golf,
Golf Cabriolet, Touran)
⇒ page 326
(Sharan) ⇒ page 328
(Scirocco) ⇒ page 330
(Tiguan) ⇒ page 332
2 - 5 Nm
3 - Mountings
❑ For charge air cooler.
4 - Seal
5 - Charge air hose
❑ Can be secured with
plug-in connectors or
screw-type clips
6 - Intake manifold connection
❑ With seals.
7 - Throttle valve module -
J338-
❑ Cleaning ⇒ page 350
❑ If renewed, erase learnt
values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
8 - 7 Nm
9 - Hose clamp
10 - Charge air hose
11 - 10 Nm
12 - Charge air pipe
13 - Charge air pressure sender - G31- with intake air temperature sender 2 - G299-
14 - 5 Nm
❑ To turbocharger
3. Charge air system 319


❑ Can be secured with plug-in connectors or screw-type clips
3.2 Assembly overview - charge air system

(Polo)
Caution


⇒ page 274
Note
The charge air cooler is removed

and installed together with the radi‐
ator.
2 - Hose clip, 5.5 Nm

3 - Charge air hose
4 - Charge air hose
5 - Throttle valve module -
J338-
tester “Guided func‐
tions”.
6 - 7 Nm
❑ With seals.

9 - 10 Nm
10 - 5 Nm
11 - Mountings
12 - 10 Nm
13 - 10 Nm
15 - Bracket
16 - 10 Nm
❑ To turbocharger
3.3 Assembly overview - charge air system (Passat, Passat CC)

⇒ page 334
2 - Bolt
❑ 5 Nm
❑ Qty. 2
3 - Mountings
❑ For charge air cooler.
❑ Installed on left and right
4 - Screw-type clamp
Caution
The screw-type clips on
the charge air pipes must
be tightened to 5.5 Nm. If
the torque is too low or
too high, the charge air
hose may slip off the
charge air pipe during
vehicle operation.
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
5 - Charge air hose
❑ Can be secured with
plug-in connectors or
screw-type clips
❑ Installation of plug-in
connectors
⇒ page 337
❑ With seals.

7 - Throttle valve module - J338-

❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
8 - Bolt
❑ 7 Nm
❑ Qty. 4
9 - Charge air hose
11 - Bolt
❑ 10 Nm
❑ Qty. 2
12 - Bolt
❑ 5 Nm
❑ Qty. 3
13 - Charge air pipe with condensate trap
❑ To remove, seal coolant hoses with hose clamps up to 40 mm - 3093-
❑ To remove, detach coolant hoses ⇒ page 322
❑ After installing, check coolant level and top up if necessary ⇒ page 197
❑ To turbocharger
❑ Can be secured with plug-in connectors or screw-type clips
❑ Installation of plug-in connectors ⇒ page 337
17 - Seal
❑ On vehicles with push-fit charge air hoses
Removal of coolant hoses on charge air pipe with condensate trap

– Seal coolant hoses with hose clamps up to 40 mm - 3093-
– Open spring-type clips -arrows-.
– Pull off coolant hose -1- and charge air pipe -2-.
– After installing, check coolant level and top up if necessary
⇒ page 197
3.4 Fitting hose connections with plug-in

connectors
Note
Air hoses can be secured with plug-in connectors or screw-type

clips.

Caution

Caution
The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe installation instructions.
Removing:
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose. Make sure
that the seal is correctly seated in the groove all around the
complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.

– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
gaged by pulling hose.
3.5 Checking charge air system for leaks


♦ Charge air system tester - V.A.G 1687- with adapter - V.A.G

1687/10- and adapter - V.A.G 1687/14-
♦ Engine bung set - VAS 6122- (not shown)

rection of -arrow-.
– Press hose locking mechanism and pull hose for crankcase
breather -1- off intake connecting pipe.
– Also pull crankcase breather hose off valve timing housing.
Caution
Crankcase breather hose must be pulled off during leak test to

prevent damage to engine.
– Seal intake connecting pipe with a bung from engine bung set
- VAS 6122- .
– Slacken spring-type clips -2- from intake hose and remove in‐
take hose.

– Renew spring-type clips -arrows- with screw-type clips from

charge air system tester - V.A.G 1687- .
– Slide the adapter - V.A.G 1687/14- onto the intake connecting
pipe and secure the hose with the relevant screw-type clip.
– Slide the adapter - V.A.G 1687/10- into the adapter - V.A.G

1687/14- and secure the adapter with the screw-type clip.
– Connect hose -1- to the charge air system tester - V.A.G
1687- .
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-

and -4-.

– Connect pressure hose -1- (compressed air supply) to charge

air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with commercially available leak detector spray or using ultra‐
sonic tester - V.A.G 1842- .
Note
♦ Slight leaks in the area of the intake connecting pipe

-arrows- are permissible, as the intake hoses are not designed
for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/6- before removing adapter.
♦ Hose connections and hoses must be free of oil and grease
before assembly.
♦ After testing compression, secure intake hoses again with
spring-type clips.

3.6 Removing and installing charge air cooler (Eos, Golf Plus, Golf, Golf Cab‐
riolet, Touran)


equipment required
Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing front bumper cover
– Remove radiator ⇒ page 271 .
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.

– Make a paper template with the specified dimensions.
– Fit the template on the plastic bracket at the front right so that
it rests against the edges at the top and left.
– Mark the intersection on the template -arrow- with a centre
punch.
– Drill a hole into the plastic bracket with a 5-mm drill bit.
– Drill or cut the hole to 16 mm.

– Remove charge air cooler downwards.
Installing
note the following:
Specified torques:
Component Nm
Charge air cooler to condenser 5
3.7 Removing and installing charge air cooler, Sharan


equipment required
Removing
Rep. gr. 50 ; Noise insulation .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing front bumper cover
– Remove radiator ⇒ page 271 .

– Remove central guide profile -A- at front end -arrows-.
– Unscrew bolts -arrows- for charge air cooler mountings.
– Unbolt condenser from charge air cooler -arrows-.
Note
The securing bolts of the condenser are difficult to access! With

the aid of a 2nd mechanic, lift the charge air cooler out of the
radiator mountings. The charge air cooler can now be moved
»back and forth« to allow access to the securing bolts.
– Secure condenser to lock carrier with cable tie.

– Take out charge air cooler from underneath.
Installing
the following:
Hose connections and hoses for charge air system must be free
of oil and grease before assembly. The seal and sealing surface
must be oiled lightly only for plug-in connectors ⇒ page 322 .
Specified torques for charge air cooler ⇒ page 319 .
Specified torques for front end ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper
3.8 Removing and installing charge air cooler (Scirocco)


equipment required
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Removing
– Remove bumper cover ⇒ Bumpers; Rep. gr. 63 ; Removing
and installing front bumper cover .
– Pull coolant hoses off radiator.
– Pull connectors off thermo switch and radiator fan.
– Remove radiator securing bolts and remove radiator with fan
downwards.
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
– Remove retaining clamp(s) for refrigerant lines.


Installing
note the following:
Specified torques:
Component Nm
3.9 Removing and installing charge air cooler, Tiguan

equipment required

Removing
– Remove bracket -1- by unscrewing securing bolts -arrows-.



– Also pull off connection at bottom of radiator.
sition .


together with radiator fan - V7- .
Note
The radiator fan - V7- and the cowling may only be renewed com‐
plete.

Installing
note the following:
Specified torques:
Component Nm
3.10 Removing and installing charge air cooler (Passat, Passat CC)


equipment required
Removing
or skid plate .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper .


side.

– Loosen hose clip -arrow-.
– Loosen hose clip on right-hand side as well and pull off charge
air hose.

– Pull off coolant hose -1- from radiator.



– Remove radiator -1- downwards.
– Undo and remove coolant pump bolts -arrows- of the radiator

support.
– Pull out bottom of radiator from mounting.
– Tilt radiator backwards.
Note
Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.
– Undo and remove condenser bolts -arrows-.

– Secure condenser to lock carrier.
– Remove radiator downwards.
Installing
following:
Caution

Note


twisted.
ed and engaged.
Fill with new coolant ⇒ page 197 .
Specified torque
Radiator to charge air cooler 5 Nm
Charge air cooler to lock carrier 5 Nm
Condenser to charge air cooler 5 Nm

24 – Mixture preparation - injection

1 Air filter
⇒ “1.1 Assembly overview - air filter”, page 339
⇒ “1.2 Assembly overview - air filter (Polo)”, page 340
⇒ “1.3 Removing and installing air filter housing”, page 341
⇒ “1.4 Removing and installing air filter housing (Polo)”,
page 342
1.1 Assembly overview - air filter

Removing and installing air filter ⇒ page 341 .
1 - 1.6 Nm
2 - Air filter upper part
3 - Vacuum hose
Caution
To avoid damage to the
connection and vacuum
hose, do not use sharp-
edged tools to remove
the hose.
❑ From camshaft housing.
❑ Remove and install us‐
ing spring-type clip pli‐
ers - VAS 5024A- .
5 - Intake hose
6 - Cover
7 - Intake air guide
8 - Air filter lower part
❑ With captive securing
bolt.
❑ With intake connection.
9 - Water drain hose
❑ When installing, arrows
on lower part of air filter
and water drainage
hose must align.
10 - O-ring
❑ Renew
11 - Filter element
1. Air filter 339

1.2 Assembly overview - air filter (Polo)
❑ Remove and install with
6340- .
2 - Intake hose
3 - Air filter upper part
4 - 1.6 Nm
❑ Tighten with torque
screwdriver - VAS
6494- .
5 - Seal
6 - Filter element
7 - O-ring
8 - Air filter lower part
⇒ page 342
9 - 8 Nm
10 - Bush
11 - Rubber mounting
12 - Rubber mounting
13 - Water drain hose
14 - O-ring
15 - Intake air duct, 3 Nm
16 - Intake connecting pipe
17 - Vacuum hose
❑ To cylinder head cover.
18 - Non-return valve
340 Rep. gr.24 - Mixture preparation - injection

1.3 Removing and installing air filter hous‐

ing
Removing
Eos and Golf Plus
– Pull coolant hose upwards out of brackets -arrows-.
– Press fastener -1- and pull intake air duct cover out upwards.
– Press fastener -arrows- and pull intake air duct upwards.

– Release spring-type clip -1- and pull intake hose and vacuum
hose off air filter.
– Loosen securing bolt -2- and pull air filter housing upwards
from locating pins -arrows-.
Installing
the following:
– Push air filter housing onto locating pins -arrows- from above.
– Tighten new securing bolt -2- to 8 Nm and slide spring-type

clip -1- with intake hose onto air filter connection.
1. Air filter 341

1.4 Removing and installing air filter hous‐

ing (Polo)
rection of -arrow-.
– Pull hose -1- off at camshaft housing.
– Open spring-type clip -2- and pull intake hose off.

– Pull intake hose -3- out of intake connection.
– Unscrew securing bolt and pull air filter housing -4- upwards.

2 Intake manifold
⇒ “2.1 Assembly overview - intake manifold”, page 343
⇒ “2.2 Removing and installing regulating flap control unit J808
and throttle valve module J338 ”, page 348
⇒ “2.3 Cleaning throttle valve module J338 ”, page 350
2.1 Assembly overview - intake manifold
Part I
Note
♦ If hoses were pulled off during repair work, check that all hoses
are firmly connected after reinstallation.
♦ Tug on hoses having catches to make sure they are securely
seated.
2. Intake manifold 343

1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - 3 Nm
3 - 7 Nm
❑ The securing bolt may
only be tightened using
an impact wrench if the
wrench speed is max.
500 rpm and a max.
specified torque of 7 Nm
is set.
5 - Seal
❑ Renew
❑ Before installing, lightly
coat seal with clean en‐
gine oil.
6 - Regulating flap control unit
- J808-
⇒ page 348
Note
Regulating flap control units with

plastic housing need not be adapted
to the engine control unit - J623- .
tester “Guided functions”.
7 - 7 Nm
❑ The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm
and a max. specified torque of 7 Nm is set.
10 - 7 Nm
❑ The securing bolt may only be tightened using an impact wrench if the wrench speed is max. 500 rpm
and a max. specified torque of 7 Nm is set.
11 - 3 Nm
12 - Intake manifold pressure sender - G71-
13 - O-ring
❑ Renew

14 - Intake manifold
Note
♦ If the intake manifold was re‐

moved, check after installing that
all hoses are securely connected
on the intake manifold.
♦ Tug on hoses having catches to
make sure they are securely
seated.
❑ To remove: Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
⇒ page 348 .
15 - 20 Nm
16 - Fuel pressure sender - G247- , 22 Nm
❑ Checking fuel pressure in high-pressure section ⇒ page 361 .
17 - 80 Nm
18 - Intake manifold lower part
Caution
If only lower part of in‐
take manifold is to be re‐
moved, ensure injectors
remain in cylinder head.
To remove, use hold-
down device - T10510-
⇒ page 346 .
Reason: After removing
injector, Teflon seal and
support washer must be
renewed ⇒ page 357 .
❑ To remove and install: using "bracket for bits 5/16""" - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 346
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 348 .
19 - Seal
❑ Renew
❑ Observe installation position
20 - 20 Nm
21 - Throttle valve module - J338-
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
functions”.
22 - 7 Nm
23 - Pressure pipe
❑ From turbocharger
24 - Retaining clip
25 - 7 Nm

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Removing
– Insert hold-down device - T10510- in the two holes on cylinder
head.
– Push pin -1- in direction of -arrow- until hold-down device is

securely seated on injectors.
– Tighten knurled nuts -1- and -2- hand-tight.
– Pull lower part of intake manifold evenly off injectors.
Installing
– Fit new gasket on cylinder head.
– Press lower part of intake manifold evenly onto injectors.
– Remove hold-down device - T10510- .
Specified torques ⇒ page 343 .
Part II
Note
♦ If hoses were pulled off during repair work, check that all hoses
are firmly connected after reinstallation.
♦ Tug on hoses having catches to make sure they are securely
seated.

1 - Union
2 - Fuel hose
❑ Low pressure
❑ To high-pressure pump
3 - Clamp
4 - Connection hose
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
5 - Activated charcoal filter sol‐
enoid valve 1 - N80-
6 - Connection hose
7 - To pressure pipe.
8 - Connecting pipe
9 - Connection hose
❑ To intake manifold con‐
nection.
10 - 8 Nm
11 - Fuel line
❑ High pressure
❑ Specified torque for un‐
ion nuts: 18 Nm.
12 - Union
❑ To intake connecting
pipe.
13 - Connection hose
14 - Non-return valve
❑ For crankcase ventilation.
16 - Charge pressure control solenoid valve - N75-
❑ To turbocharger
19 - Union
20 - 5 Nm
❑ To turbocharger
22 - Union
23 - Union

❑ To charge pressure control solenoid valve - N75- .
26 - Union
❑ Connected to valve timing housing.
2.2 Removing and installing regulating flap

control unit - J808- and throttle valve
module - J338-
Note
To remove throttle valve module - J338- , regulating flap control

unit - J808- must first be removed.


Removing regulating flap control unit - J808-

rection of -arrow-.
– Remove securing bolts -1-.
– Pull off all connectors and hose connections on intake con‐

necting pipe -4- and regulating flap control unit - J808- .
– Detach spring-type clips and pull off hose -2- on activated
charcoal filter system solenoid valve 1 - N80- and pressure
pipe -3-.
– Unscrew securing bolt for pressure pipe -3- on turbocharger
and pull pressure pipe -3- off.
– Unscrew intake connecting pipe securing bolts -arrows- and

pull intake connecting pipe upwards with regulating flap con‐
trol unit - J808- .
– Unscrew securing bolts -arrows-.

Removing throttle valve module - J338-
– Detach coolant hose -1- from hose clips.

– Pull connector -2- off intake air temperature sender 3 - G520-

with intake manifold pressure sender 3 - G583- .
– Remove charge air hose -3- from throttle valve module - J338-
and charge air pipe.
– Unscrew securing bolts -arrows- and pull throttle valve module

- J338- from intake manifold connection.
Installing
note the following:
♦ Seals and O-rings must be renewed and coated lightly with
clean engine oil before installing.

Specified torques:
If a new regulating flap control unit or throttle valve module has
been installed:
– Erase learnt values and adapt engine control unit - J623- to
regulating flap control unit and throttle valve module ⇒ Vehicle
diagnostic tester “Guided functions”.
Note
Regulating flap control units with plastic housing need not be

adapted to the engine control unit - J623- .
2.3 Cleaning throttle valve module - J338-
Note
♦ If a new engine control unit - J623- is installed the throttle valve

module must be adjusted. Adaptation must be performed only
with a new or cleaned throttle valve module, because soiling
or coking at the end stop of the throttle valve can lead to in‐
correct adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.
– Remove throttle valve module ⇒ page 348 .

– Open throttle valve by hand and lock in open position using a

suitable object (e.g. wood or plastic wedge) -arrow-.
WARNING
Acetone is highly inflammable. Please comply with the acci‐

dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
– Thoroughly clean throttle valve housing, especially around the

closed throttle valve -arrows- using commercially available
acetone according to DIN 53247 and a brush.
– Wipe off throttle valve housing using a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester “Guided func‐
tions”.

3 Injectors
Safety precautions ⇒ page 5 .
General notes on injection
♦ The engine control unit - J623- is capable of self-diagnosis.
Before carrying out repairs and for fault finding, first read event
memory. Also the vacuum hoses and connections must be
checked (unmetered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel
pump is activated for 2 seconds to build up pressure in the fuel
system.
⇒ “3.1 Assembly overview - fuel rail with injectors”, page 352
⇒ “3.2 Removing and installing injectors”, page 354
⇒ “3.3 Renewing seals on injectors”, page 357
3.1 Assembly overview - fuel rail with injectors

1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Spring element
❑ Renew each time after
removing lower part of
intake manifold.
❑ Ensure proper seating
on injector.
3 - Injector, cylinder 4 - N33-
❑ Injector, cylinder 1 -
N30-
N31-
N32-
❑ With Teflon seal and
support washer.
❑ After removing injector,
Teflon seal and support
washer must be re‐
newed ⇒ page 357 .
injectors ⇒ page 354 .
4 - Intake manifold lower part
Caution
If only lower part of in‐
take manifold is to be re‐
moved, ensure injectors
remain in cylinder head.
To remove, use hold-
down device - T10510-
⇒ page 346 .
Reason: After removing
injector, Teflon seal and
support washer must be
renewed ⇒ page 357 .
❑ To remove and install: using "bracket for bits 5/16""" - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 354
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 348 .
Caution
If only lower part of intake manifold is to be removed, ensure

injectors remain in cylinder head.
To remove, use hold-down device - T10510- ⇒ page 346 .
Reason: After removing injector, Teflon seal and support
washer must be renewed ⇒ page 357 .
3. Injectors 353
Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Removing
– Insert hold-down device - T10510- in the two holes on cylinder
head.
– Push pin -1- in direction of -arrow- until hold-down device is

securely seated on injectors.
– Tighten knurled nuts -1- and -2- hand-tight.
– Pull lower part of intake manifold evenly off injectors.
Installing
– Fit new gasket on cylinder head.
– Press lower part of intake manifold evenly onto injectors.
– Remove hold-down device - T10510- .
Specified torques ⇒ page 343 .
3.2 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 5 .
Note
Teflon seal on injector must be renewed each time after removing

injector ⇒ page 357 .


♦ Tool set - T10133-
Removing
Remove air filter ⇒ page 341 .
Remove regulating flap control unit - J808- and throttle valve
– Remove intake manifold and lower part of intake manifold
⇒ page 343 .
– Press O-ring upwards by hand as shown, and remove it from
injector.
– Screw slide hammer - T10133/3- to puller - T10133/15- .
– Then insert puller - T10133/15- into groove -arrow- on injector.
3. Injectors 355
– Pull injector out by tapping carefully.

Installing
– Thoroughly clean injector holes in cylinder head using nylon

brush - T10133/4- .
– Check plastic support washer for damage, renew if necessary
⇒ page 357 .

– Renew spring element -arrow- and Teflon seal each time after
removing injectors ⇒ page 357 .
– Renew O-rings between injector and lower part of intake mani‐
fold and moisten slightly with clean engine oil.
Note
The Teflon seal on the injector must not be oiled or greased.
– Push injector into cylinder head bore to stop by hand.
Note
The injector must insert easily. If necessary wait until the seal has
contracted sufficiently.
– Ensure correct position of injectors in cylinder head.

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 343 .
– Install intake manifold ⇒ page 343 .
– Install regulating flap control unit - J808- and throttle valve
Install air filter ⇒ page 341 .
– Connect ⇒ Vehicle diagnostic tester and perform Guided
Function “Deleting injector adaptation values”.
Note
A new generation of engine control units has been introduced

(UDS => Unified Diagnostic Service). Only engine control units of
this new generation must be adapted.
3.3 Renewing seals on injectors

♦ Tool set - T10133-
Procedure
Renewing Teflon seal
Remove air filter ⇒ page 341 .
3. Injectors 357
Remove regulating flap control unit - J808- and throttle valve

– Remove intake manifold and lower part of intake manifold
⇒ page 343 .
– Remove injectors ⇒ page 354 .
– Clean injector carefully.
– Carefully cut open seal with a knife as shown -arrow-. Avoid
contact between knife blade and valve body under all circum‐
stances.
– Remove old seal and clean seal groove in area of seal
-arrow-. Remove coking deposits using a brass wire brush.
– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
assembly sleeve - T10133/6- (knurled end faces seal -1-),
gently slide seal onto assembly cone - T10133/5- as far as
possible.
– Turn assembly sleeve - T10133/6- around (knurl no longer

points to seal), and push seal -1- to end of assembly cone -
T10133/5- .
– Now place assembly cone - T10133/5- with seal onto injector
from front. Slide seal further onto injector using assembly
sleeve - T10133/6- .

The seal is not yet seated in its groove.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
– Slide seal into annular groove by hand.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibrating sleeve - T10133/7- again.

– Now push calibrating sleeve - T10133/8- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibrating sleeve - T10133/8- again.
Now the Teflon seal has correct installation dimensions.

Renewing support washer
– Remove O-ring -3-.
– Cut support washer -2- open with a small pair of side cutters
and remove it.
– Pull spring element -1- off injector and replace with retaining
plate - T10133/12- .
– Place new support washer -1- onto assembly cone -
T10133/13- and position onto injector as shown.
3. Injectors 359
– Slide support washer -1- into first groove -arrow- on injector

using calibration sleeve - T10133/17- (knurled side points to
injector).
– Now turn calibration sleeve - T10133/17- around (knurled side
no longer points to injector). Slide calibration sleeve over sup‐
port washer -1- in direction of -arrow- to stop on retaining plate
- T10133/12- .
– Pull calibrating sleeve - T10133/17- down again.
The support washer now has correct installation dimensions.
– Now position a new spring element -1- for retaining plate -

T10133/12- and position a new O-ring -3- in front of support
washer -2-.
Note
The Teflon seal -arrow- must not be oiled to install injector.
– Install injectors ⇒ page 354 .

– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 343 .
– Install intake manifold ⇒ page 343 .
– Install regulating flap control unit - J808- and throttle valve
Install air filter ⇒ page 341 .

4 Senders and sensors

⇒ “4.1 Checking fuel pressure sender”, page 361
⇒ “4.2 Actuator for structure-borne sound R214 and control unit
for structure-borne sound J869 (Polo, left-hand drive)”,
page 364
⇒ “4.3 Assembly overview - actuator for structure-borne sound
R214 and control unit for structure-borne sound J869 (Polo, right-
hand drive)”, page 366
4.1 Checking fuel pressure sender

♦ Double hex socket 1/2”, 27 mm - VAS 5301/7-

♦ Digital pressure gauge - VAS 6394/1-
♦ Test adapter - VAS 5570-
WARNING

bar):
approx. 6 bar. The appropriate procedure is described in the
chapter on releasing pressure in the high-pressure section
⇒ page 6 .
Procedure
rection of -arrow-.
4. Senders and sensors 361

– Remove fuel pressure sender - G247- -1-.
– Instead of fuel pressure sender - G247- , screw in adapter -

VAS 6394/2- and tighten to 22 Nm.
– Open cover -2- of digital pressure gauge - VAS 6394/1- and

tighten fuel pressure sender - G247- to digital pressure gauge
to 22 Nm.
– Screw pressure line -1- of digital pressure gauge - VAS
6394/1- hand-tight to adapter - VAS 6394/2- .
– Connect test adapter - VAS 5570- between fuel pressure

sender - G247- -1- and connector.


VAS 5051B- -1- as follows:
– Push diagnostic cable connector -2- onto diagnostic connec‐
tion in driver footwell.
– Switch on ignition.
Engine control units KWP (Keyword Protocol)
– Press following keys on display in succession:
Vehicle self-diagnosis
Vehicle self-diagnosis
01 - Engine electronics
011 - Measured values
– Enter '248' (or '140' for engine code CKMA) and confirm with
Q.
Display field 3 shows the actual value reported to the vehicle by

the fuel pressure sender - G247- .
Engine control units UDS (Unified Diagnostic Service)
Note
A new generation of engine control units has been introduced

(UDS => Unified Diagnostic Service). These new-generation en‐
gine control units require a different procedure for requesting the
required values.
– Press following keys on display in succession:

Guided function
– Confirm the test version and the brand.

– Specify vehicle model.
– Select model year.
– Determine engine version.
– Specify “engine” as vehicle system to be used.
Read measured values
– Follow the programmed steps of the tester until step »Select

displayable measured values«.
– Search for “IDE00589 Fuel Pressure” in plain text.
Done
Read
Continuation for all engine control unit versions:

– Switch on digital pressure gauge - VAS 6394/1- by pressing

key -A- briefly once.
Note
When button -A- is pressed for 2 seconds, the illumination will be

switched on for 20 seconds.
Digital pressure gauge - VAS 6394/1- should display 0 bar; if this

is not the case, press key -C- briefly once for zero point compen‐
sation.
– Start engine.
– Compare pressure displayed by digital pressure gauge - VAS
6394/1- with actual value of vehicle diagnosis, testing and in‐
formation system - VAS 5051B- .
The pressures may deviate by up to 5 bar.
If pressures do not correspond, fuel pressure sender - G247-
must be renewed.
WARNING

bar):
⇒ page 6 .
Note
Once the high-pressure in the high-pressure area is reduced,

open the system immediately as the pressure will rise again due
to warming.
– Renew fuel pressure sender - G247- and again compare both

measured values.
If measured values again fail to correspond:
– Check wiring ⇒ Vehicle diagnostic tester.
If measured values correspond:
– Further testing is carried out with “Guided Fault Finding” in
⇒ Vehicle diagnostic tester.
4.2 Actuator for structure-borne sound - R214- and control unit for structure-
borne sound - J869- (Polo, left-hand drive)

1 - 8 Nm
2 - 8 Nm
3 - Actuator for structure-borne
sound - R214-
❑ Fitting location: in ple‐
num chamber
Removing and installing
– Remove wiper arms ⇒

Electrical system; Rep.
gr. 92 ; Windscreen wip‐
er system; Removing
and installing wiper
arms .
– Remove plenum cham‐
ber cover and plenum
chamber bulkhead ⇒
Body - front; Rep. gr.
50 .
4 - Connector
5 - Bracket
6 - Connector
❑ For removing, push the
catch outwards.
7 - Control unit for structure-
borne sound - J869-
num chamber

er system; Removing and installing wiper arms .
– Remove plenum chamber cover ⇒ Body - front; Rep. gr. 50 .
8 - Bracket for control unit for structure-borne sound - J869-

❑ is removed and installed together with the control unit for structure-borne sound - J869- .

4.3 Assembly overview - actuator for structure-borne sound - R214- and control
unit for structure-borne sound - J869- (Polo, right-hand drive)
1 - Bracket for control unit for

structure-borne sound - J869-
❑ is removed and installed
together with the control
unit for structure-borne
sound - J869- .
2 - Control unit for structure-
borne sound - J869-
num chamber

er system; Removing
and installing wiper
arms .
– Remove plenum cham‐

ber cover ⇒ Body - front;
Rep. gr. 50 .
3 - Connector
❑ For removing, push the
catch outwards.
4 - 8 Nm
5 - Bracket
6 - Actuator for structure-borne
sound - R214-
num chamber

gr. 92 ; Windscreen wiper system; Removing and installing wiper arms .
– Remove plenum chamber cover and plenum chamber bulkhead ⇒ Body - front; Rep. gr. 50 .
7 - Connector
8 - 8 Nm

5 High-pressure pump
⇒ “5.1 Assembly overview - high-pressure pump”, page 367
⇒ “5.2 Removing and installing high-pressure pump”, page 368
5.1 Assembly overview - high-pressure

pump
WARNING

bar):
Before opening the high-pressure section, e.g. to remove the
high-pressure pump, fuel rail, injectors, the fuel lines, or the
⇒ page 6 .
1 - Roller tappet
❑ Lightly coat with engine
oil when installing.
2 - O-ring
❑ Renew
❑ Lightly coat with engine
oil when installing.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-
Caution
Only grasp high-pres‐
sure pump on housing
when removing and in‐
stalling!
When the high-pressure
piston spring package
loosens the high-pres‐
sure pump will leak and
must be replaced.
4 - 20 Nm
❑ Tighten bolts evenly.
5 - Union
❑ High pressure
6 - Union nut, 18 Nm
❑ Observe safety precau‐
tions ⇒ page 5 .
❑ Counterhold when loos‐
ening connection to
high-pressure pump.
5. High-pressure pump 367

7 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
8 - Union
❑ Low pressure
5.2 Removing and installing high-pressure

pump
Removing
Note safety precautions ⇒ page 5 .
Observe rules for cleanliness ⇒ page 7 .
rection of -arrow-.
WARNING

bar):
⇒ page 6 .

– Separate fuel supply line -arrow-.

– Remove intake connecting pipe ⇒ Item 8 (page 344) .
– Pull connector and fuel supply line -arrows- off high-pressure

pump.
Note
Catch escaping fuel in a cloth.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.
– Loosen union nuts -3- and -1- of high-pressure line.
– Evenly unscrew securing bolts -arrows-.

– Pull high-pressure pump -3- and roller tappet -1- out of cam‐
shaft housing.
Installing
Caution
Only grasp high-pressure pump on housing when removing

and installing!
When the high-pressure piston spring package loosens the
high-pressure pump will leak and must be replaced.

note the following:
Note
♦ Moisten high-pressure pump roller tappet with clean engine

oil.
♦ The high-pressure pump O-ring must be renewed.
– Slide roller tappet -1- into camshaft housing.
– Insert new, lubricated O-ring -2- in groove of high-pressure

pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
– Screw in securing bolts -arrows- by hand until bolt heads are

seated on flange.
– Tighten securing bolts -arrows- evenly until flange is seated
on camshaft housing.

– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install wiring guide -2- and fit clip -4- on high-pressure line.
Specified torque of wiring guide securing bolt: 8 Nm
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten union nut -1- of high-pressure line to 18 Nm.

– Tighten union nut -3- of high-pressure line to 18 Nm.
– Secure fuel supply line and connector -arrows- on high-pres‐

sure pump.
– Reconnect fuel supply line -arrow-.

– Install intake connecting pipe and air filter ⇒ page 341 .

6 Engine control unit - J623-

⇒ “6.3 Removing and installing engine control unit J623 (Eos)”,
page 376
⇒ “6.4 Removing and installing engine control unit J623 with pro‐
tective housing (Eos► 10.2008)”, page 377
⇒ “6.1 Removing and installing engine control unit J623 (Golf
Plus, Touran)”, page 372
tective housing (Golf Plus, Touran)”, page 374
⇒ “6.5 Removing and installing engine control unit J623 (Tiguan)”,
page 379
tective housing (Tiguan)”, page 380
⇒ “6.7 Removing and installing engine control unit J623 (Sciroc‐
co)”, page 382
tective housing (Scirocco► 09.2008)”, page 383
⇒ “6.9 Removing and installing engine control unit J623 (Golf, Golf
Cabriolet)”, page 385
⇒ “6.10 Removing and installing engine control unit J623 (Passat,
Passat CC)”, page 386
⇒ “6.11 Removing and installing engine control unit J623 with
protective housing (Golf, Eos 11.2008►, Scirocco 10.2008►, Pas‐
sat, Passat CC, Golf Cabriolet)”, page 387
⇒ “6.12 Removing and installing engine control unit J623 (Polo)”,
page 390
protective housing (Polo)”, page 391
⇒ “6.14 Removing and installing engine control unit J623 (Shar‐
an)”, page 392
protective housing (Sharan)”, page 393
6.1 Removing and installing engine control

unit - J623- (Golf Plus, Touran)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Remove wiper arms and plenum chamber cover ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .

– Loosen securing bolts -arrows- of control unit cover.

– Then remove securing nuts for control unit bracket -arrows-.
– Release connectors on engine control unit and pull off con‐

nector.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
– Tighten securing bolts -arrows- to 10 Nm.
6. Engine control unit J623 373


– Install plenum chamber bulkhead ⇒ General body repairs;
– Install wiper arms and plenum chamber cover ⇒ Electrical

unit - J623- with protective housing (Golf
Plus, Touran)
♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
Removing
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.

nector.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.

– Install cover of protective housing.

– Tighten new shear-head bolts -arrows- evenly until heads

shear off.

unit - J623- (Eos)
unit”.
Removing
– Remove securing bolts -1- and remove cover plate -2-.
– Release front connector -1- from engine control unit and pull
it off.
– Lever up catch -2- slightly.
– Then press engine control unit out of retainer
-in direction of arrow-.
– Then release rear connector on engine control unit and pull it
off.
Installing
– Fit rear connector to engine control unit and lock in position.
– Push engine control unit onto bracket.
– Fit front connector to engine control unit and lock it in position.
– Install cover plate for connectors.



unit - J623- with protective housing
(Eos► 10.2008)
♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

unit”.
Removing
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat

output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.
– Lever up protective housing using screwdriver -A- and in side‐

wards motion pull off bracket -arrow-.
– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Now release connector on engine control unit and pull off con‐
nector.
Installing
– Push engine control unit onto bracket.

– Press catch -1- against engine control unit.

– Push protective housing onto bracket.
– Tighten new shear-head bolts -1- evenly until heads shear off.

unit - J623- (Tiguan)
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051 B- and car‐
ry out the guided function “Renew control unit”.
Removing
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
cover
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.

– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
– Slide engine control unit -1- into retaining frame in

– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.

– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

unit - J623- with protective housing (Ti‐
guan)
If you wish to replace the engine control unit, connect the vehicle
diagnosis, testing and information system - VAS 5051B- and carry
out the guided function “Renew control unit”.
♦ Grip pliers
Removing
– Remove wiper arms, ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
cover.

– Unscrew bolts -1-.

– Cover the plenum chamber with a clean cloth so that it is not
scratched.
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly.
– Bend the upper ends -1- of locking clip outwards.

– Remove shear-head bolts -2- using grip pliers and remove
locking clip.
– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- in retaining

frame until it engages.
– Tighten the retaining frame.


-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off.

unit - J623- (Scirocco)
unit”.
Removing
– Press retaining frame down in -direction of arrow- and remove
engine control unit.
– Push connector locking devices in direction of -arrow-, and pull

connectors off.
Installing


onto stop in direction of -arrow-.
– Insert engine control unit into retaining frame and press re‐
taining frame upwards in -direction of arrow-

(Scirocco► 09.2008)
unit”.
Removing

– Remove shear-head bolts -arrows- using pliers and remove

locking clips.

connectors off.
Installing

– Fit the two locking clips over the connector and secure with
new shear-head bolts -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.


unit - J623- (Golf, Golf Cabriolet)
unit”.
Removing

connectors off.
Installing



unit - J623- (Passat, Passat CC)
unit”.
Removing
– Remove windscreen wiper arms ⇒ Electrical system; Rep. gr.
92 ; Windscreen wiper system; Removing and installing wiper
arms .
– Remove plenum chamber cover ⇒ General body repairs; Rep.
gr. 50 ; Front body, plenum chamber cover .


connectors off.
Installing

– Fit plenum chamber cover ⇒ General body repairs; Rep. gr.
50 ; Front body, plenum chamber cover .
– Fit windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wiper
arms

(Golf, Eos 11.2008►, Scirocco
10.2008►, Passat, Passat CC, Golf
Cabriolet)
unit”.
Removing
arms .
Golf, Golf Cabriolet, Eos, Scirocco
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .

Passat, Passat CC
– Remove plenum chamber cover ⇒ General body repairs; Rep.
gr. 50 ; Front body, plenum chamber cover .
– Unscrew shear-head bolts -arrows- using pliers.
– Insert screwdriver between both locking plates -arrow-.

– Carefully press screwdriver in direction of -arrow- and bend
retaining bow -1- upwards at the same time.
– Bend retaining bow -1- in direction of -arrow- until it can be

pulled off connectors.


connectors off.
Installing

– Fit retaining bow -1- onto connectors and press it in direction

of -arrow-.
– Guide pin -2- to stop into hole on engine control unit.
– Secure retaining bow with shear-head bolts to engine control

unit -arrows-.
– Tighten shear-head bolts evenly until heads shear-head off
-arrows-.

Golf, Golf Cabriolet, Eos, Scirocco
Passat, Passat CC
– Fit plenum chamber cover ⇒ General body repairs; Rep. gr.
50 ; Front body, plenum chamber cover .
– Fit windscreen wiper arms ⇒ Electrical system; Rep. gr. 92 ;
Windscreen wiper system; Removing and installing wiper
arms

unit - J623- (Polo)
unit”.
Removing
nector.
– Press clips -arrows A- outwards and pull engine control unit

out to side -B-.
Installing
– Insert new engine control unit and press to the left.
– Fit connectors and lock in position.
– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Read control unit event memory again.


unit - J623- with protective housing (Po‐
lo)
unit”.
Removing
– Raise latch -1- and remove engine control unit -2-.
– Unscrew shear-head bolts -1- using a pair of pliers.
– Release connector from engine control unit and pull off.
Note
If engine control unit is to be renewed, shear-head bolts -2- must

also be unscrewed.
Installing
– Fit connectors and lock in position.
– Push the protective housing over the engine control unit.
– Install retainer for protective housing using new shear-head
bolts.
– Tighten shear-head bolts evenly until heads shear off.
– Insert engine control unit -2- into bracket on plenum chamber

bulkhead until it audibly engages in latches -1-.
– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester “Gui‐
ded functions”.
memory ⇒ Vehicle diagnostic tester “Guided fault finding”.
– The readiness code must be generated if the event memory
has been cleared.
– Read control unit event memory again.


unit - J623- (Sharan)
Note
Removing and installing anti-theft engine control unit

⇒ page 393 .
– If you wish to renew the engine control unit, connect ⇒ Vehicle

diagnostic tester and carry out guided function “Renew engine
control unit”.
Removing
arms .
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
view - plenum chamber cover .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Raise engine control unit -1- in front area in
– Pull engine control unit forwards out of the side guides -2-.
– Slide connector locking devices -1- on engine control unit in

-direction of arrow- and pull off both connectors.
Installing
Specified torque of securing nuts for retaining frame: 6 Nm
– Attach connectors to engine control unit and slide locking de‐
vices inwards until they engage.

– Push engine control unit -1- into side guides -2- in the
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview
- plenum chamber cover .

(Sharan)
♦ Grip pliers
– If you wish to renew the engine control unit, connect ⇒ Vehicle
diagnostic tester and carry out guided function “Renew engine
control unit”.
Removing
arms .
terior; Rep. gr. 64 ; Flush-bonded windows; Assembly over‐
view - plenum chamber cover .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Raise engine control unit -1- in front area in
– Pull engine control unit forwards out of the side guides -2-.

– Bend upwardly projecting tabs -1- of locking bar outwards.

– Unscrew shear-head bolts -2- using a pair of pliers and remove
locking bar -3-.
– Slide connector locking devices -1- on engine control unit in

-direction of arrow- and pull off both connectors.
Installing
Specified torque of securing nuts for retaining frame: 6 Nm
– Attach connectors to engine control unit and slide locking de‐
vices inwards until they engage.
– Screw on a new locking bar -3- with new shear-head bolts

-2- and tighten bolts uniformly until just before heads shear off.
Disregard item -1-.
– Push engine control unit -1- into side guides -2- in the
rior; Rep. gr. 64 ; Flush-bonded windows; Assembly overview
- plenum chamber cover .

26 – Exhaust system
1 Exhaust pipes and silencers
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamping sleeve and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
Caution

⇒ “1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco,

Golf, Touran, Golf Cabriolet)”, page 396
⇒ “1.2 Assembly overview - silencers (Tiguan)”, page 397
⇒ “1.3 Assembly overview - silencers (Polo)”, page 398
⇒ “1.4 Assembly overview - silencers (Sharan)”, page 399
⇒ “1.5 Assembly overview - silencer (Passat, Passat CC)”,
page 400
⇒ “1.6 Removing and installing front exhaust pipe (Tiguan with
four-wheel drive)”, page 401
⇒ “1.7 Removing and installing front exhaust pipe (Golf Plus, Eos,
Scirocco, Golf, Tiguan, Touran, Golf Cabriolet)”, page 402
⇒ “1.8 Removing and installing front exhaust pipe (Sharan)”, page
403
⇒ “1.9 Removing and installing (Passat, Passat CC)”, page 404
⇒ “1.10 Separating exhaust pipes, silencers (Tiguan)”,
page 406
⇒ “1.11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scir‐
occo, Golf, Touran, Golf Cabriolet)”, page 407
⇒ “1.12 Separating exhaust pipes, silencers (Polo)”, page 409
⇒ “1.13 Separating exhaust pipes, silencers (Sharan)”,
page 410
⇒ “1.14 Separating exhaust pipes/silencers (Passat, Passat CC)”,
page 411
⇒ “1.15 Aligning exhaust system free of stress (Passat, Passat
CC)”, page 413
⇒ “1.16 Installation position of clamp”, page 414
1. Exhaust pipes and silencers 395

1.1 Assembly overview - silencer (Golf Plus, Eos, Scirocco, Golf, Touran, Golf
Cabriolet)
1 - Mounting
2 - 25 Nm
3 - Bracket
❑ Observe installation po‐
sition
4 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers
⇒ page 407
5 - 25 Nm
6 - Bracket
sition
7 - Mounting
8 - Rear silencer
9 - Mounting
396 Rep. gr.26 - Exhaust system

1.2 Assembly overview - silencers (Tiguan)
1 - Exhaust pipe with centre

and rear silencers
tem free of stress
2 - 20 Nm
3 - Bracket
4 - 25 Nm
5 - Bracket
6 - Mounting
7 - 25 Nm
8 - Bracket
9 - 25 Nm
10 - Tunnel cross-piece
11 - 25 Nm

1.3 Assembly overview - silencers (Polo)
1 - Bracket with mounting

2 - Rear silencer
tem free of stress
❑ Separating exhaust
pipe and rear silencer
⇒ page 409 .
3 - Bracket
sition
4 - 25 Nm
5 - Mounting
6 - 25 Nm
7 - 25 Nm

1.4 Assembly overview - silencers (Sharan)
1 - of the exhaust pipe with

flexible connection (de-cou‐
pling element)
2 - 25 Nm
❑ Renew
3 - Front silencer
4 - Separation point
❑ Marked by indentation
on exhaust pipe.
❑ As standard, exhaust
pipe and front silencers
are installed as a single
component. In repair ca‐
ses the exhaust pipe
and front silencer are
supplied individually
with a double clamp for
connecting together.
❑ Cut through exhaust
pipe with pneumatic sa‐
bre saw - V.A.G 1523A-
or chain pipe cutter -
VAS 6254- at right
angles at the separating
point ⇒ page 410 .
5 - Clamping sleeve
❑ Installation position and
specified torque
⇒ page 410
❑ Tighten bolted connec‐
tions evenly.
6 - Rear silencer
tem free of stress
7 - Mounting
8 - Seal
❑ Renew

1.5 Assembly overview - silencer (Passat, Passat CC)
1 - Clamping sleeve
specified torque
⇒ page 414
tem free of tension
⇒ page 413 .
❑ Comply with instruc‐
tions for alignment of
rear silencer
⇒ page 411
2 - Mounting
3 - Centre silencer
tem free of tension
⇒ page 413 .
❑ Separating centre and
rear silencers
⇒ page 411
4 - Bolt
❑ 25 Nm
❑ Qty. 2
5 - Bracket
sition
6 - Clamping sleeve
❑ For repair cases
❑ Loosen to enable align‐
ment of exhaust system free of stress ⇒ page 413
❑ Installation position and specified torque ⇒ page 414
❑ Comply with instructions for alignment of rear silencer ⇒ page 411
❑ During production, front and rear silencers are installed as a single component. In case of repair, the
front and rear silencers are supplied individually and with a double clamp for connecting.
❑ Cut through exhaust pipe with e.g. pneumatic sabre saw - V.A.G 1523A- or chain pipe cutter - VAS 6254-
at right angles at the separating point ⇒ page 411 .
7 - Rear silencer
❑ Comply with instructions for alignment of rear silencer ⇒ page 411
❑ Aligning exhaust system free of tension ⇒ page 413 .
8 - Bracket
❑ Observe installation position
9 - Mounting
10 - Bolt
❑ 25 Nm
❑ Qty. 2
11 - Bolt
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Wheel suspension, rear .

❑ 90 Nm + 90°
❑ Renew after each removal
❑ M12 x 1.5 x 110
12 - Bracket
1.6 Removing and installing front exhaust

pipe (Tiguan with four-wheel drive)
Removing
– Remove right drive shaft ⇒ Repairing drive shafts; Rep. gr.
40 ; Removing and installing drive shafts .
– Remove securing bolts -1- and -2- for exhaust pipe mounting.
– Remove exhaust pipe mounting downwards.




– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
Installing
Installation is performed in the reverse order of removal.
Specified torques:
Pendulum support ⇒ page 65
Exhaust pipe ⇒ page 417

pipe (Golf Plus, Eos, Scirocco, Golf, Ti‐
guan, Touran, Golf Cabriolet)
Removing
Tiguan


– Remove exhaust pipe -1-.
Installing
Specified torques:
Exhaust pipe ⇒ page 415

pipe (Sharan)
Removing
drive shafts .


backwards on exhaust pipe with front silencer -1-.
– Pull exhaust pipe with front silencer slightly backwards.
– Push exhaust pipe with front silencer backwards out of mount‐

ing -1-.
– Remove exhaust pipe with flexible connection (de-coupling
element).
Installing
Specified torques
⇒ page 420
⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts
1.9 Removing and installing (Passat, Pas‐

sat CC)

or skid plate .


verter - G130- .

Caution



– Unscrew nuts -arrows A- on exhaust pipe -1-.

– Push front exhaust pipe -2- backwards out of mounting
-arrows B -.
– Remove front exhaust pipe forwards.
Installation
following:
Specified torque
Front exhaust pipe to catalytic converter 25 Nm
Exhaust pipe to front exhaust pipe 25 Nm
Pendulum support ⇒ page 67
1.10 Separating exhaust pipes, silencers (Ti‐

guan)
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
Or
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure

– Cut through exhaust pipe at separating point -2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position clamping sleeve centrally at side marks -1- and -3-
when installing.
– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Threaded connection faces to rear.
– Aligning rear silencer free of stress ⇒ page 407
Specified torques ⇒ page 414
Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
1.11 Separating exhaust pipes/silencers

(Golf Plus, Eos, Scirocco, Golf, Touran,
Golf Cabriolet)

Or
Procedure
– Cut through exhaust pipe at cutting point -arrow 2- using chain-

1523A- .
– Position clamp -4- centrally at side marks when installing, ar‐
rows -1- and -3-.
– Install clamp so that bolt ends do not protrude beyond lower

edge of clamp -arrow-.
Specified torques ⇒ page 414


1.12 Separating exhaust pipes, silencers

(Polo)
♦ For individual renewal of the rear silencer, a cutting point is
provided in the connecting pipe.
Or
Procedure

– Cut through exhaust pipe at cutting point -arrow 2- using chain-

1523A- .
– Position clamping sleeve centrally at side marks -1- and -3-
when installing.
– Install clamp so that bolt ends do not protrude beyond lower

edge of clamp -arrow-.
Mounting position and specified torque of the clamping sleeve
⇒ page 414

1.13 Separating exhaust pipes, silencers

(Sharan)
♦ The exhaust pipe can be cut through at the point marked in
order to renew the exhaust pipe or the front silencer separate‐
ly.

Or
Procedure
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
– Cut through exhaust pipe at right angles at separating point

-2- using pneumatic sabre saw - V.A.G 1523A- or chain-type
pipe cutter - VAS 6254- .
– Position repair double clamp at side marks -1- and -3- when
installing.
– Install double clamp so that bolt ends do not protrude beyond

lower edge of double clamp -arrow-.
– Align exhaust system free of stress.
Mounting position and specified torque of the clamping sleeve
⇒ page 414
1.14 Separating exhaust pipes/silencers

(Passat, Passat CC)


Or
BlueMotion vehicles from 11.2010
– Remove panelling of rear axle ⇒ Wheel suspension, rear;
Rep. gr. 42 ; Assembly overview: Attachments for subframe
of BlueMotion vehicles .
– Remove additional underbody panels on left and right ⇒ Body,
front; Rep. gr. 50 ; Additional underbody panels (BlueMotion)
- Assembly overview for vehicles from 11.2010 .
– Cut through exhaust pipe at separating point -arrow 2- at right
angles e.g. with pneumatic sabre saw - V.A.G 1523A- or chain
pipe cutter - VAS 6254- .
Separating point on exhaust pipe
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
– Position repair double clamp centrally between outer mark‐

ings.

– Align rear silencer -1- so that dimensions -a- are identical.

– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
• Nuts are below
– Ensure correct mounting position and specified torque
⇒ page 414 .
– Aligning rear silencer ⇒ page 412
– Aligning exhaust system free of tension ⇒ page 413 .
Specified torque
Double clamp ⇒ page 414
1.15 Aligning exhaust system free of stress

(Passat, Passat CC)
• Engine must be cold
– Loosen threaded connections -3- and -4- of front clamping
sleeve -1- ⇒ Item 6 (page 400) .
-Arrow- points in direction of travel
– Align front clamping sleeve -1- to marking -A- on front exhaust
pipe -2-.
• Dimension -a- = ⇒ page 414
• Do not allow the bolts must be on the right and the ends to
protrude beyond the lower edge of the clamp.
– Push rear silencer forwards into clamp until dimension -a-

15…17 mm is attained between mountings for body and rear
silencer. -Arrow- points in direction of travel.
– Aligning rear silencer ⇒ page 412
– Note installation position and specified torque of clamping
sleeve ⇒ page 414 .

1.16 Installation position of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.

Clamp -A- with 2 individual clips.
Installation dimensions -a- 5 mm (only for front clamp)
Clamp -B- with continuous clip.
Installation dimensions -a- 8.5 mm (only for front clamp)
Installation dimension -a- for vehicles with marking -A- on front

exhaust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
3 - Securing nut
4 - Securing nut
a - Installation dimension
A - Marking
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right
Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.

2 Exhaust gas cleaning

⇒ “2.1 Assembly overview - exhaust gas treatment (Golf Plus,
Eos, Scirocco, Golf, Touran, Tiguan, Golf Cabriolet)”, page 415
⇒ “2.2 Assembly overview - exhaust gas treatment (Tiguan with
four-wheel drive)”, page 417
⇒ “2.3 Assembly overview - exhaust gas treatment (Polo)”, page
419
⇒ “2.4 Assembly overview - exhaust gas treatment (Sharan)”,
page 420
⇒ “2.5 Assembly overview - exhaust gas treatment (Passat, Pas‐
sat CC)”, page 421
⇒ “2.6 Removing and installing catalytic converter (Polo)”,
page 423
⇒ “2.7 Removing and installing (Passat, Passat CC)”, page 424
2.1 Assembly overview - exhaust gas treatment (Golf Plus, Eos, Scirocco, Golf,
Touran, Tiguan, Golf Cabriolet)
1 - Heat shield
2 - 10 Nm
3 - Lambda probe after catalyt‐
ic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
4 - Seal
❑ Renew
5 - Exhaust pipe
6 - Clamping sleeve
specified torque
⇒ page 414
tions evenly.
7 - 25 Nm
❑ Renew
8 - Mounting
9 - 25 Nm
10 - Exhaust pipe
❑ With flexible connection
(de-coupling element).
❑ Do not bend flexible
connection more than
10° - otherwise it can be
damaged.
2. Exhaust gas cleaning 415

11 - 23 Nm
❑ Renew
12 - 23 Nm
❑ Renew
13 - Catalytic converter with exhaust pipe
14 - 25 Nm
15 - Bracket
16 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
17 - 10 Nm
18 - 25 Nm
Observe tightening sequence: items -A- to -I- ⇒ page 277 .
Caution
a new turbocharger.
❑ The turbocharger and the exhaust manifold can only be renewed together.
20 - Bracket
Note
♦ There is no need to reinstall the
retainer in cases of repair

2.2 Assembly overview - exhaust gas treatment (Tiguan with four-wheel drive)
1 - Seal
❑ Renew
2 - 25 Nm
❑ Renew
3 - Exhaust pipe
4 - Clamping sleeve
specified torque
⇒ page 414
tions evenly.
5 - 10 Nm
6 - 25 Nm
7 - Washer
8 - Pin
9 - Bonded rubber mounting
10 - 25 Nm
11 - Bracket
12 - Lambda probe after cata‐
lytic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
13 - 25 Nm
14 - Spring
15 - Bracket
16 - 25 Nm
17 - Mounting
18 - Exhaust pipe
❑ With flexible connection (de-coupling element).
❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
19 - 23 Nm
❑ Renew
20 - 23 Nm
❑ Renew

21 - Catalytic converter with exhaust pipe

22 - 25 Nm
23 - Bracket
24 - 10 Nm
26 - 25 Nm
Caution
a new turbocharger.
28 - Bracket
Note
♦ There is no need to reinstall the
retainer in cases of repair
29 - Heat shield

2.3 Assembly overview - exhaust gas treatment (Polo)
1 - Heat shield
2 - 10 Nm
Caution
a new turbocharger.
❑ The turbocharger and

the exhaust manifold
can only be renewed to‐
gether.
4 - Seal
❑ Renew
5 - 25 Nm
❑ Renew studs and fas‐
tening nuts.
Observe tightening sequence:
items -A- to -I- ⇒ page 277 .
Screw the studs into cylinder

head until they project only
25 mm.
6 - Clamping sleeve
specified torque
⇒ page 414
tions evenly.
7 - Catalytic converter with
front silencer
❑ With flexible connection (de-coupling element).
❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
8 - Mounting
10 - 25 Nm
11 - Bracket
12 - 10 Nm
13 - Seal
❑ Renew
14 - 23 Nm
❑ Renew
15 - Lambda probe after catalytic converter - G130-

16 - 10 Nm
2.4 Assembly overview - exhaust gas treatment (Sharan)
1 - Heat shield
2 - Seal
❑ Renew
3 - Seal
❑ Renew
4 - Catalytic converter with ex‐
haust pipe
5 - 25 Nm
❑ Renew
6 - 25 Nm
7 - To front silencer
8 - 25 Nm
9 - Mounting
10 - Exhaust pipe
❑ With flexible connection
(de-coupling element).
❑ Do not bend flexible
connection more than
10° - otherwise it can be
damaged.
⇒ page 402
11 - 23 Nm
❑ Renew
12 - Seal
❑ Renew
13 - Lambda probe after cata‐
lytic converter - G130- , 50 Nm
14 - 10 Nm
15 - Bracket
❑ For electrical cables
17 - 25 Nm

Caution
a new turbocharger.
19 - 10 Nm
2.5 Assembly overview - exhaust gas treatment (Passat, Passat CC)
1 - Heat shield
2 - Nut
❑ 10 Nm
❑ Qty. 3
3 - Bolt
❑ 10 Nm
❑ Qty. 2
4 - Seal
❑ Renew
5 - Exhaust pipe
6 - Seal
❑ Renew
7 - Stud
8 - Nut
❑ 23 Nm
❑ Renew
❑ Qty. 4
9 - Catalytic converter
⇒ page 424
10 - Front exhaust pipe
❑ With decoupling ele‐
ment.
❑ Do not bend flexible joint
more than 10°. Other‐
wise, it can be dam‐
aged.
⇒ page 404
11 - Lambda probe after catalytic converter - G130- , 50 Nm
12 - Nut
❑ 23 Nm
❑ Renew
❑ Qty. 2

13 - Bolt
❑ 25 Nm
❑ Qty. 2
14 - Mounting
❑ Attached to subframe
15 - Nut
❑ 23 Nm
❑ Renew
❑ Qty. 2
16 - Seal
❑ Renew
17 - Bolt
❑ 25 Nm
❑ Qty. 2
18 - Bolt
❑ 10 Nm
❑ Qty. 2
19 - Bracket
21 - 25 Nm
Caution
a new turbocharger.
23 - Seal
❑ Renew

2.6 Removing and installing catalytic con‐

verter (Polo)
Removing
rection of -arrow-.
– Remove noise insulation securing bolts -arrows-.

converter - G130- .

– Also disconnect connector for Lambda probe - G39- .

– Unscrew securing bolts -1- for charge air pipe.
– Unscrew securing bolts -4- and remove bracket -5-.
– Pull upper charge air hose off turbocharger.
– Press front exhaust pipe mountings from pins.
– Loosen securing nuts for clamping sleeve -arrows- and slide

clamping sleeves backwards.
– Remove catalytic converter with front silencer downwards.
Installing
Specified torques:
Assembly overview - catalytic converter and add-on parts (Polo)
⇒ page 419
2.7 Removing and installing (Passat, Pas‐

sat CC)
Removing
or skid plate .

– Lever off engine cover panel at points -1-.

– Pull off cover panel forwards in direction of -arrow-.
– Unbolt heat shield above turbocharger -arrows-.

converter - G130- .
– Also disconnect connector for Lambda probe - G39- .
– Unscrew bolts -1- for charge air pipe.
– Unscrew bolts -4- and remove bracket -5-.
– Pull off charge air hose on top of turbocharger, loosening clip
to do so.
Installation
following:
Specified torque
Front exhaust pipe to catalytic converter 25 Nm
Catalytic converter to turbocharger 23 Nm


Exhaust pipe to front exhaust pipe 25 Nm

28 – Ignition system
1 Ignition system
General notes on ignition system
♦ The engine control unit - J623- is capable of self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ In some tests, a fault may be detected and stored by the en‐
gine control unit - J623- . Therefore, after completing all the
checks and repairs, read the event memory and clear it if nec‐
essary .
⇒ “2.2 Safety precautions when working on ignition system”, page
5.
⇒ “1.1 Assembly overview - ignition system”, page 427
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 428
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
430
⇒ “1.4 Test data, spark plugs”, page 432 .
1.1 Assembly overview - ignition system
1. Ignition system 427

1 - Connector
❑ Black, 4-pin.
❑ With assembly tool -
T10118- .
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
⇒ page 428
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Connector contacts are
gold-plated.
4 - Knock sensor 1 - G61-
❑ Connector contacts are
gold-plated.
❑ To remove, remove su‐
percharger ⇒ page 296 .
5 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
6 - Connector
❑ Black, 3-pin.
❑ For Hall sender - G40- .
7 - Hall sender - G40-
8 - O-ring
9 - 10 Nm
10 - Spark plug, 25 Nm
❑ Remove and install with spark plug socket and extension - 3122 B-
❑ Type and electrode gap ⇒ page 432 .
11 - Wiring guide
❑ Bolt to camshaft housing with 5 Nm torque.
12 - Earth cable
❑ Loosen or tighten only with ignition switched off.
13 - 10 Nm
❑ Loosen or tighten only with ignition switched off.
1.2 Removing and installing ignition coils

with output stage
428 Rep. gr.28 - Ignition system

Note
The ignition coil housings with output stages have been modified.
As a result, these ignition coils can only be removed and installed
with puller - T10094 A- . The previous puller - T10094- can con‐
tinue to be used if modified as described below.
– Remove marked area -2- using suitable workshop equipment

to attain the new nominal dimension -B- of 18 mm.
– Add the letter A to the end of tool designation -1-.
Removing
rection of -arrow-.

– Unscrew securing bolts -1- from crankcase breather union and

non-return valve.
– Pull off connector -2- from turbocharger air recirculation valve
- N249- and pull off hose connection -3-.
– Carefully pull hose -4- off intake manifold connection.
– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism, and pull off
connector.
Installing
– Fit puller - T10094 A- on ignition coil with output stage.
– Slide connector on ignition coil with output stage until it audibly
engages.
– Press ignition coil with output stage into cylinder head in di‐
rection of -arrow-.
– Push rubber grommet -1- into hose -2-.

– Push hose -2- onto intake manifold connection -3-.
Specified torques of securing bolts for crankcase breather con‐
nection and for non-return valve: 10 Nm
1.3 Removing and installing engine speed

sender - G28-
The engine speed sender - G28- is located on the sealing flange
on the flywheel end of the crankcase.


equipment required

Removing
– Remove compressor ⇒ page 298 .
– Remove supercharger (Tiguan with four-wheel drive)
⇒ page 306 .

– Pull off connector -1- from engine speed sender - G28- .

– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installing
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
quence.
1.4 Test data, spark plugs

Engine code CAVA, CAVB, CAVC, CTHA, CTHB, CTHC, CKMA
CAVD, CAVE CTHD, CTHE, CTKA,
CNWA
Firing order 1-3-4-2
Spark plugs
VW part number 8)*) 101 905 622 03C 905 601 B 101 905 626 A
Electrode gap 0.8 … 0.9 mm 0.7…0.8 mm 0.5 … 0.6 mm
Specified torque 25 Nm
Change interval ⇒ Maintenance ; Booklet ; Time or distance dependent additional work
8) Current spark plugs ⇒ Electronic parts catalogue (ETKA)

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.6 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

1.10 Separating exhaust pipes, silencers (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Engine code and engine number can be found on the sticker

Vehicles for certain export countries have no type plate. Fitting

Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Volkswagen Technical Site: https://vwts.ru 1. Engine number/engine data 1

Engine code CAVA CAVD CAVC CAVB CAVE CKMA

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

2 Rep. gr.00 - Technical data

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

1. Engine number/engine data 3

Engine CTHA CTHB CTHC CTHD, CNWA CTHE

Volkswagen Technical Site: https://vwts.ru

4 Rep. gr.00 - Technical data

2.1 Safety regulations for working on fuel

Observe the following points during all installation work, in par‐

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

Fuel system is under pressure! Wear eye protection and gloves

♦ Even before work commences, the extraction hose of an ac‐

2.2 Safety precautions when working on ig‐

If test and measuring instruments are operated from the front

2.3 Releasing pressure in high-pressure

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

– Connect ⇒ Vehicle diagnostic tester and perform Guided

The fuel lines are pressurized! Wear protective goggles and

– Wrap a clean cloth around the connection and carefully open

If the event memory was cleared, the readiness code must be

6 Rep. gr.00 - Technical data

3 General repair instructions

3.1 Rules for cleanliness

3. General repair instructions 7

10 – Removing and installing engine

1.1 Removing engine (Golf Plus, Eos, Scir‐

♦ Crankcases were installed with different size threaded holes.

Converting engine support - T40075-

8 Rep. gr.10 - Removing and installing engine

Special tools and workshop

♦ Engine support - T40075- with adapters /4, /5, /6 or engine

1. Removing and installing engine 9

♦ Hose clamp pliers - VAS 6340-

The battery earth must be disconnected for the remaining proce‐

10 Rep. gr.10 - Removing and installing engine

– Unbolt heat shield over turbocharger -arrows-.

– Release hose guides -arrows- and remove coolant hose -1-

– Remove hose -2- from activated charcoal filter system sole‐

1. Removing and installing engine 11

– Pull vacuum and breather hoses off engine.

– Open all line guide fasteners -arrows-.

12 Rep. gr.10 - Removing and installing engine

– Remove hoses for activated charcoal filter -arrows-.

– Pull activated charcoal filter -1- upwards out of bracket.

– Unbolt bracket -arrows-.

– Pull connector off Lambda probe after catalytic converter -

1. Removing and installing engine 13

– Unbolt exhaust pipe together with flexible joint -arrows-.

– Loosen securing bolts of clamp -arrows- and pull exhaust pipe