Engine Manual PDF

Service
Workshop Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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21 - Turbocharging/supercharging
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24 - Mixture preparationrise-dinjection ran
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26 - Exhaust system
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B803919C7

Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 4
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2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 5
2.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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3.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 36
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.4 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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3.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.6 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Renewing oil seal for balance shaft (inlet side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5 Checking radial clearance of nconrods
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1.2 Removing and installing upper timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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2.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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2.2 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.4 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.5 Checking chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectne 113
3.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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3.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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3.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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4.3 Installing ball for sliding piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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4.4 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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4.5 Removing and installing camshaft control valve 1 N205 / exhaust camshaft control valve 1
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4.6 Removing and installing actuator for camshaft adjustment N580 / N605 . . . . . . . . . . . . . . 165
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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 170
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.6 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.3 Removing ageand

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switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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3.2
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4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 185
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4.3 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 186
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4.4 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 186
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4.5 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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4.6 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 188
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4.7 Removing and installing stage 3 oil pressure switch F447 . . . . . . . . . . . . . . . . . . . . . . . . 189
4.8 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

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1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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1.4 Flushing cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1.5 Flushing cooling system, quick reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s 224
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4
Prote
cted Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AG.
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2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.6 Removing and installing auxiliary pump for heating V488 . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.7 Removing and installing coolant shut-off valve N82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.8 Removing and installing coolant valve for gearbox N488 . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.9 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 239
2.10 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 241
2.11 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 242
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.2 Removing and installing coolant pipe at front of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.3 Removing and installing coolant pipe on top of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3.4 Removing and installing coolant pipe on radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.3 Assembly overview - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.5 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.6 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.7 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
1.3 Adjusting charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Contents iii
- Edition 12.2017
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.2 Releasing high pressure in fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.g.en. A. G . ..V.o.lk.sw
. a. g.e.n.A.G.d.o . . . . . . . . 288
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3.1 Assembly overview - intake manifold . . . . . . . . . . . .y.V. . . . . . . . . . . . . . . . . . . . . . .no. t.g.u . . . 288
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3.2 Removing and installing intake manifold . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te 289
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3.3 Removing and installing throttle valve moduleauGX3 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 ra
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3.4 Cleaning throttle valve module . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
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4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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4.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
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4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
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4.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
hole
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4.5 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
es, in part or in w
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5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
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5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
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5.3 Removing and installing fuel pressure sender for low-pressure G410 . . . . . . . . . . . . . . . . 312
5.4 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
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G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.5 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 314
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6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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6.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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7.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 t. Cop py
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7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 gh ht
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8 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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8.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 325
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1.2 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.5 Align end exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.6 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.7 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
2.3 Removing and installing exhaust flap control unit J883 / J945 . . . . . . . . . . . . . . . . . . . . . . 341
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.1 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 344
iv Contents
AG. Volkswagen A
Golf 2013 ➤ , Golf 2015o➤ agen
ksw, Golf 2017 ➤ , Golf Variant
es n 2014 ➤ , Golf V ...
G do
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4-cyl. direct injection engine (2.0 l, 4 V, turbocharger,
ed by chain drive, generation III) Volkswagen
ua
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s
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- Edition
tee
o 12.2017
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3.3 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 344
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3.4 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
spec
es, in part or in w
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 347
t to the co
1.3 Removing and installing knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
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1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
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Contents v
- Edition 12.2017
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vi Contents
- Edition 12.2017
00 – Technical data
1 Identification
(VRL011114; Edition 12.2017)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

Engine number
The engine number (“code letters” and “serial number”) can be
found at the joint between the engine and gearbox.
The engine code is also stamped on the cylinder block behind the
oil filter.
In addition, there is a sticker on the right of the timing chain cover
with “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine and
are stamped on the engine. The fourth digit shows the engine
output and torque and varies according to engine control unit. The
four-character engine code can be found on the identification
plate as well as on the vehicle data sticker. It can also be read
from the engine control unit.
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♦ Fitting locations of vehicle data sticker auth or
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♦ ⇒ Maintenance ; Booklet 36.1 ; Vehicle data sticker
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♦ ⇒ Maintenance ; Booklet 43.1 ; Vehicle data sticker

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Codes CJXB CJXC CYFB
Displacement l 1.984 1.984 1.984

Power kW at rpm 206/5100 to 6500 221/5500 to 6200 215/5400 ... 6200 t to the co
Torque Nm at rpm 380/1800 to 5100 380/1800 to 5500 380/1900 ... 5300
rrectne
Bore ∅ mm 82.5 82.5 82.5

Stroke mm 92.8 92.8 92.8
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Compression ratio 9.3:1 9.3:1 9.3:1

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RON 981) 981) 981)

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Ignition/injection system FSI FSI FSI

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MPI MPI MPI

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Exhaust gas recirculation No No No

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Exhaust gas temperature regulation No No No

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Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

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Knock control yes yes yes
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Charge air cooler yes cted
yes yes
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Lambda regulation yes yes yes
Camshaft timing adjustment yes yes yes
Variable intake manifold yes yes yes
Secondary air system No No No
Valves per cylinder 4 4 4
1. Identification 1
- Edition 12.2017
Codes CJXB CJXC CYFB

Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder shut-off No No No
• 1) Unleaded petrol RON 95 can also be used, though power
is reduced
Codes CJXD CJXG DJHA

Power kW at rpm 213/5400 to 6500 228/5800 to 6500 228/5500 to 6500
AG. Volkswagen AG d
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Torque Nm at rpm 380/1850 olks
wa 5100 380/1850
oe s noto 5700 400/2000 to 6500
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Bore ∅ mm ed
b 82.5 82.5 ran a 82.5
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Stroke tho
mm 92.8 92.8 o 92.8
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Compression ratio ss 9.3:1 9.3:1 9.3:1
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Charge air cooler yes yes yes
Lambda regulation yes yes yes
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Variable intake manifold yes yes yes
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2

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Codes DJHB DJJA DLRA

Power kW at rpm 213/5400 to 6500 215/5400 to 6200 215/5400 to 6200
Torque Nm at rpm 380/1850 to 5300 380/1900 to 5300 380/1900 to 5300
Bore ∅ mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 9.3:1 9.3:1 9.3:1
RON 981) 95 95
MPI
er er er
Charge air cooler yes yes yes
2 Rep. gr.00 - Technical data

AG. Volkswagen A - Edition 12.2017
n G do
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Codes DJHB by DJJA ua
ran DLRA
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Lambda regulation au yes
th yes yes
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Variable intake manifold
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2
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1. Identification 3
- Edition 12.2017
2 Safety information
⇒ “2.1 Safety regulations for working on fuel supply”, page 4
⇒ “2.2 Safety measures when working on vehicles with a start/
stop system”, page 4
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 5
⇒ “2.4 Safety precautions when working on ignition system”, page
5
⇒ “2.5 Safety precautions when working on the cooling system”,
page 6
2.1 Safety regulations for working on fuel

supply
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
WARNING
Risk of injury due to fuel which is under very high pressure

♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
AG. Volkswagen AG d
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♦ Prior to opening the high-pressure
ris
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ho eo
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residual pressure of approx.
ss
a 6 bar. Procedure c
⇒ page 284 .
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2.2 Safety measures when working on ve‐

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WARNING
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Risk of injury due to automatic start of engine on vehicles with

a start/stop system.
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♦ In vehicles with an activated start/stop system (indicated

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start automatically.
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ercia
♦ Therefore, ensure that the start/stop system is deactivated

m
when working on vehicle (switch ignition off, switch ignition

at
om
io
on again as required).
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Prote AG.
Rep. gr.00 - Technical data
- Edition 12.2017
2.3 Safety precautions when using testers

and measuring instruments during a
road test
WARNING
Risk of accidents due to distraction and inadequate securing

of test and measuring equipment.
♦ Operation of test and measuring equipment while driving
results in distraction.
♦ Increased risk of injury due to inadequately secured test
and measuring equipment.
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♦ Test and measuring
olks
wageequipment must always
does
not be secured
on the reard bseat.
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♦ A second
ut
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eo
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equipment.
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♦ The person operating the test and measuring equipment
pt
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must be seated in the rear.

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♦ Never operate the test and measuring equipment while
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sitting in the front passenger seat.

wit
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ole,
♦ In the event of an accident, the person may receive seri‐

ous injuries when the front passenger airbag is triggered. spec
t to the co
2.4 Safety precautions when working on ig‐

rrectne
nition system
s
To prevent injuries to persons and/or damage to the injection and

s o
cial p
ignition system, the following must be observed:

f inform
mer
♦ Persons wearing a cardiac pacemaker must at all times main‐

atio
tain a safe distance from high-voltage components such as

om
ignition system and xenon lights.

n
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or
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♦ Do not open any fuel line connections while the engine is run‐
t
sd
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♦ Always switch off the ignition before connecting or discon‐

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necting electrical wiring for the injection or ignition system or
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♦ If the event memory has been cleared, a new readiness codeProte
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agen
must be generated.
♦ Always switch off ignition before cleaning engine.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
♦ If the engine is to be turned at starter speed without actually
starting (e.g. compression test), disconnect the four connec‐
tors from the ignition coils. Use puller - T40039- to do this. Also
remove fuse from fuel pump control unit - J538- .
2. Safety information 5
- Edition 12.2017
2.5 Safety precautions when working on the

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

Danger of scalding by steam and hot coolant.
AG. Volkswagen n AG do
wage e
Cover filler cap on expansion tank Vol with a cloth and open care‐ ot gu
ks sn
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fully to release pressure. rised ara
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Caution
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Danger of overheating due to incorrectly fitted cap.
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♦ You should hear and feel it click into place.
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spec
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cial p
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Prote AG.

- Edition 12.2017
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 7
⇒ “3.2 Foreign objects in engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Routing and attachment of lines”, page 8
⇒ “3.5 Fitting radiator and condensers”, page 8
⇒ “3.6 Checking vacuum system”, page 8
3.1 Rules for cleanliness
Note
Even slight soiling can cause faults. You must therefore comply
with the following cleanliness rules when working on the fuel sup‐
ply system, injectors or the turbocharger:
♦ Carefully clean connection points and the surrounding area

with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them over.
Use only lint-free cloths. Volkswa AG. gen AG
agen does
♦ If repair work cannot be performed immediately, Volcarefully cov‐
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er or seal components. d by ara
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♦ Install only clean parts; do not remove au new parts from pack‐
t ra
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aging until immediately before installing. Do not use parts that
ce
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have been stored outside their packaging (e.g. in tool boxes).

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♦ When the system is open, do not work with compressed air or
erm
move the vehicle. ab

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♦ Make sure that no fuel gets onto the fuel hoses. Should this
, is n
h re
occur, the fuel hoses must be cleaned immediately.
hole
spec
♦ Protect disconnected electrical connectors from dirt and water,

es, in part or in w
t to the co
and reconnect them only when dry.
3.2 Foreign objects in engine

rrectness of i
♦ To prevent the ingress of foreign bodies during work on the

l purpos
engine, seal open channels of the intake and exhaust sections

with suitable bungs, for example from the engine bung set -
VAS 6122- .
nform
mercia
at
om
io
Note
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ate
In the event of mechanical damage to the turbocharger, refer to

do
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⇒ page 259 .
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3.3 Contact corrosion
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Contact corrosion can occur if non-approved fasteners are used
co lksw
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on the vehicle (bolts, nuts, washers etc.). Prote AG.
For this reason, only connecting elements with a special surface

coating have been fitted.
3. Repair instructions 7
- Edition 12.2017
In addition, rubber, plastic and adhesives are made of non-con‐

ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .
♦ We recommend only original genuine parts. They have been
tested and are compatible with aluminium.
♦ We recommend the use of VW accessories.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
3.4 Routing and attachment of lines

♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐
coal filter system and electrical wiring etc. before removal so gen AG
. Volkswagen AG
does
they can be re-installed in the original positions and correctly Volkswa not
gu
connected. Where necessary, make sketches or take photo‐ ed by ara
nte
graphs. thoris
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♦ Because of the limited space in the engine compartment,
ss en‐ c
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le
sure sufficient clearance to all moving or hot components to

un
pt
prevent damage to the lines.
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3.5 Fitting radiator and condensers
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ility
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Even if installed correctly, the radiator, the condenser and the
h re
hole
charge air cooler may have small dents in their fins. This does not
spec
mean that these components have been damaged. It is not per‐
es, in part or in w
missible to renew radiators, condensers or charge air coolers only
t to the co
because of such minor dents.
3.6 Checking vacuum system
rrectness of i
l purpos
Special tools and workshop equipment required

♦ Hand operated vacuum pump - VAS 6213-
nform
mercia
a
com
tion in
r
te o
thi
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Prote AG.
Procedure
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those leading to other components.

- Edition 12.2017
– If pressure cannot be built-up using hand vacuum pump - VAS

6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.
AG. Volkswagen AG d
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3. Repair instructions 9
- Edition 12.2017
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Separating engine and gearbox”, page 18
⇒ “1.3 Securing engine on engine and gearbox support”,
page 23
⇒ “1.4 Installing engine”, page 25
1.1 Removing engine
Special tools and workshop

equipment required
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♦ Release lever - 80 - 200-
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Prote AG.
♦ Spring-type clip pliers - VAS 6362-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Stepladder - VAS 5085-
♦ Drip tray for workshop hoist - VAS 6208-
10 Rep. gr.10 - Removing and installing engine

- Edition 12.2017
♦ Engine support - T10359 -

♦ Pin - T10359/2-
♦ Adapter - T10359/3-
♦ Safety glasses
♦ Safety gloves
Procedure
Note
The engine is removed downwards with gearbox.
– Remove engine cover panel ⇒ page 38 .

– Remove air filter housing together with air intake hose
⇒ page 287 .
– Unscrew bolts -arrows-.
– Unclip lower part of air duct -1- and remove it.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
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Use removal
s lever - 80-200- to unclip the binding clips.
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– Disconnect connectors -1 and 2- from engine control unit -

J623- .
rrectness of i
– Remove connectors -3 and 4- from retainer, and disconnect

l purpos
them.
– Move electrical lines free.
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mercia
a
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Prote AG.
1. Removing and installing engine 11

- Edition 12.2017
– Release catches -arrows- and detach cover -1- for electronics

box in engine compartment.
– Using a screwdriver, release catch -arrow-. Pull cover -1- for

electronics box in engine compartment upwards.
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– Remove nut -arrow-, detach electrical wiring and movessclear.
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t to the co
rrectness of i
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Vehicles with manual gearbox
nform
– Disconnect electrical connector -2-.
mercia
– Push back cover for battery positive terminal -1-, and unbolt
at
om
io
battery positive cable from starter solenoid switch.

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c
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– Unscrew nut -3- and remove earth wire.

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Depending on vehicle version, the earth wire is secured to the
ht
pyri by
Vo
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starter bolt.
c by lksw
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Prote AG.

- Edition 12.2017
– Disconnect connectors -1 and 2- at front left of gearbox. agen

AG. Volkswagen AG d
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olksw not
– Disconnect gear selector cable and gate selector cable ed b from
y V gu
ara
gearbox. Then, unbolt cable support bracket, and horislay it to one nte
eo
side together with cables ⇒ Rep. gr. 34 ; Selector
aut mechanism; ra
c
Removing and installing selector mechanism s .
s
ce
le
un
pt
– Detach line leading to clutch slave cylinder ⇒ Rep. gr. 30 ;
an
d
itte
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Clutch mechanism; Removing and installing clutch slave cyl‐
erm
ab
inder .
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spec
t to the co
Vehicles with dual clutch gearbox
rrectne
– Push back cover for battery positive terminal -3-, and unbolt
s
battery positive cable from starter solenoid switch.
s o
cial p
f in
– Loosen nut -arrow-, and remove earth wire.
form
mer
atio
om
n
Note
c
i
or
n thi
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sd
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Depending on vehicle version, the earth wire is secured to the

i
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pr
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starter bolt.
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Caution pyri by
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Prote AG.
Risk of damage to the control unit (mechatronic unit) due to
electrostatic discharge
♦ Do not touch contacts in the gearbox connector with
hands.
– Touch earth connection (without gloves) in order to discharge

yourself.
– Disconnect connector -2- for mechatronic unit for dual clutch
gearbox - J743- . To do this, turn rotary fastener in anti-clock‐
wise direction.
– Disconnect selector lever cable from gearbox, and pull it out
of cable support bracket ⇒ Rep. gr. 34 ; Selector mechanism;
Removing and installing selector mechanism .
Continuation for all
– Remove electrical connectors -1 and 2- from retainer, and dis‐

connect them. Move lines to one side.

- Edition 12.2017
– Separate vacuum hose -2-.

– Press release tabs on vacuum hose -1-. Remove hose from
vacuum pump.
– Remove radiator cowl ⇒ page 256 .
– Release hose clips -1- and -2-, and remove air intake hose.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .
– Lay coolant hose -3- to one side.

– Release hose clip -2-.
– Separate electrical connector -1- from charge pressure sender
- G31- . agen
AG. Volkswagen AG d
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– Remove right air intake pipe. ed by gu
ara
ris nte
o eo
– Remove front parts of left and right front wheel housing
aut liners
h
ra
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
s housing
s c
liner; Assembly overview – front wheel housing liner . ce
le
un
pt
an
d
itte
– Remove subframe without steering rack ⇒ Running gear, y li

erm
ab
axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐ ility
ot p
ling subframe without steering rack . wit

is n
h re
– Remove front exhaust pipe with catalytic converter

ole,
spec
⇒ page 339 .
t to the co
Make yourself familiar with the relevant safety precautions before

starting work on the cooling system ⇒ page 6 .
rrectne
– Open filler cap -arrow- for coolant expansion tank.

– Place drip tray for workshop hoist - VAS 6208- underneath.
ss o
cial p
f inform
mer
atio
om
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c
i
or
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Prote AG.

4-cyl. direct injection engineo(2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
AG. V lkswagen AG d
lkswagen oes
n - Edition 12.2017
o ot g
yV ua
edb ran
– Disconnect
ho
ris electrical connector -1-. Lift retaining teeclip -2-, and
loosen
aut hose clip -3-. or
ac
ss
– Pull off coolant hose and connection, and drain coolant.
ce
e
nl
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an
itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
– Lift retaining clips -arrows- and disconnect coolant hoses from
l purpos
heat exchanger for heater.

– Hold coolant hoses downwards to allow coolant to drain.
nform
ercia
Make yourself familiar with the relevant safety precautions before

m
at
starting work on the fuel system ⇒ page 4 .
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– Disconnect hose couplings -1- and -2- ⇒ Fuel supply system
agen
Prote AG.
- petrol engines; Rep. gr. 20 ; Plug-in connectors; Discon‐
necting plug-in connectors . Detach hoses from coolant ex‐
pansion tank -3-.
– Loosen hose clips -1 and 2-, and detach coolant hoses.

Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant AG. Vo2014
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agen chain drive,Ageneration
4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, does
III) Volkswagen R GmbH
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- Edition 12.2017 sedb ara
n
ri tee
ho
ut or
– Lift retaining clip -arrow- and disconnect
ss coolant hose (top left)
a ac
from radiator.
ce
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un
pt
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d
Vehicles with dual clutch gearbox
itte
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ab
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t to the co
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– Release retaining clips -1 and 2-, and detach coolant hoses
s o
for auxiliary radiator at front left.
cial p
f inform
Continuation all vehicles
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Prote AG.
– Unscrew bolts -arrows- for gearbox mounting approx. 2 turns.
– Unscrew bolts -arrows- for engine mounting approx. 2 turns.

– Remove air conditioner compressor (with refrigerant lines con‐
nected) from bracket, and tie it up to right side ⇒ Air condi‐
tioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor from and
to bracket .
– Unbolt drive shafts from flange shafts on left and right ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft .
– Tie up drive shafts to rear.
Note
Make sure not to damage the surface protection of the drive

shafts.

- Edition 12.2017
– Remove bolt -arrow- and push bracket for electrical wiring

harness to one side.
– Secure adapter -T10359/3- to engine support - T10359- , as

shown in illustration.
– Use locking element -A- from gearbox support - 3282- to se‐
cure pin -T10359/2- to engine support.
– Insert engine support - T10359- in engine and gearbox jack -
V.A.G 1383 A- . . Volkswage AG n AG d
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– Fit engine support - T10359- to cylinder block. Screw bolt -A-
with spacer sleeve into cylinder block. rrectne
Component Specified torque

s
Bolt -A- 20 Nm
s o
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– Secure engine with locking element -B-, and slightly lift engine
form
mer
with gearbox.
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t.
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Cop py
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pyri by
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by c lksw
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Prote AG.

- Edition 12.2017
– Remove bolts -arrows- for engine mounting.
– Remove bolts -arrows- securing gearbox mounting.
Caution
Risk of damage to the vacuum lines, electrical wiring and the

engine compartment
♦ Check that all vacuum lines and electrical wiring between
engine, gearbox and body have been detached.
♦ When lowering, carefully guide engine/gearbox assembly
out of engine compartment.
– Carefully lower engine/gearbox assembly.
AG. Volkswagen AG d
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1.2 Separating engine and gearbox

⇒ “1.2.1 Separating engine and gearbox, vehicles with manual
nf
ercia
gearbox”, page 18
rm
m
atio
m
⇒ “1.2.2 Separating engine and gearbox, vehicles with dual clutch

o
n in
c
gearbox”, page 21
or
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1.2.1 Separating engine and gearbox, vehi‐

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Special tools and workshop equipment required t. C rig
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Prote AG.

- Edition 12.2017
♦ Workshop hoist - VAS 6100- agen

AG. Volkswagen AG d
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♦ Lifting tackle - T40013-
rrectness of i
l purpos
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♦ Hook - 10 - 222 A /2-
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Prote AG.
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10359- .
– Release electrical wires from retainer -arrow- and lay them to
one side.

- Edition 12.2017
– Unscrew bolts -1 and 2-, and remove starter from gearbox.
– Move electrical wiring harnesses -1, 2- clear at air pipe.

– Loosen screw-type clip -3-.
– Remove bolts -arrows- and detach air pipe.
– Unscrew bolts -arrows- and detach gearbox support.
AG. Volkswagen AG d
agen oes
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– Attach lifting tackle - T40013- to gearbox and close lock.

y li
erm
ab
ility
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /

ot p
wit
2- to lifting tackle.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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c
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ate
do
priv
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for
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t.
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Cop py
t. rig
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pyri by
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Prote AG.

- Edition 12.2017
– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.
Note
Ignore -items 4, 5- and -A-.
– Pull gearbox off engine.
1.2.2 Separating engine and

AG. Volgearbox,
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♦ Adapter - 10 - 222 A /20-

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♦ Hook -2024 A /1-

- Edition 12.2017
♦ Engine bung set - VAS 6122-
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10359- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
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– Unscrew nuts -arrows-, and remove bracket at front of sump.
rrectness of i
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Note
The studs are welded to the front of the sump.

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Note
Place a cloth underneath to absorb escaping coolant.
– Loosen hose clips -arrows- and remove coolant hoses from

gear oil cooler.
– Unscrew bolts -1- and lay coolant valve for gearbox - N488- to
one side.

- Edition 12.2017
– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and

secure with pin -arrow-.
– Attach hook -2024 A /1- gto
en workshop
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– Unscrew bolts -1 to 8- securing gearbox to engine.
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– Pull gearbox off engine.

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1.3 Securing engine on engine and gearbox support

- Edition 12.2017

equipment required
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♦ Lifting tackle - 2024 A-

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Procedure
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• Gearbox detached from engine ⇒ page 18 .
– Release catch -arrow- and detach mounting -1- for engine
cover panel.

- Edition 12.2017
– Attach lifting tackle - 2024 A- to engine on workshop hoist -

VAS 6100- .
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
Risk of accidents due to loose components of the lifting tackle

♦ The support hooks and pins on the lifting tackle must be
secured with locking pins -arrows-.
– Using workshop hoist - VAS 6100- , lift engine off engine and
gearbox jack - V.A.G 1383 A- . wage
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– Remove dowel sleeves for gearbox,
horis and, on gearbox side, bolt nte
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engine to engine and gearbox
s aut support - VAS 6095- . ra
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1.4 Installing engine rrectness
Procedure
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Caution
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Observe the following during all assembly work, particularly in

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the engine compartment due to the restricted space:

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♦ Route lines of any kind and cables so that original routing

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is restored.
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♦ Ensure that there is sufficient clearance to all moving or
ht. rig
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Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Reinstall all cable ties in the same locations when installing.

- Edition 12.2017
– Guide engine/gearbox assembly into body.

– First screw bolts -arrows- for engine mountings into stop by
hand.
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cial p
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AG. Volkswagen AG d
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Golfed b2013 ➤ , Golf 2015 ➤ , Golf 2017gu➤
y ara, Golf Variant 2014 ➤ , Golf V ...
nte
ris(2.0 l, 4 V, turbocharger, chain drive, generation
4-cyl. direct injection enginetho eo III) Volkswagen R GmbH
u ra
ss a c - Edition 12.2017
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nl
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– First screw bolts -arrows- for gearbox mountings into stop by
an
itte
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hand.
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Note
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hole
spec
The bolts are tightened to final torque only after adjusting the as‐
es, in part or in w
t to the co
sembly mountings ⇒ page 29 .
– Remove engine bracket - T10359- from engine.
rrectness of i
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
l purpos
40 ; Drive shaft; Assembly overview - drive shaft .

Vehicles with manual gearbox:
nf
ercia
or
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
m
m
atio
m
Removing and installing clutch slave cylinder .

o
n in
or c
– Install cables with cable support bracket ⇒ Rep. gr. 34 ; Se‐
thi
te
sd
lector mechanism; Assembly overview - selector cables .
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Vehicles with dual clutch gearbox:
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– Install and adjust selector lever cable ⇒ Rep. gr. 34 ; Selector Cop py
t. rig
mechanism; Removing and installing selector lever cable . opyri
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Continued for all vehicles:
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cted agen
Prote AG.
– Install air conditioner compressor ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air conditioner compressor; Assembly overview
- drive unit of air conditioner compressor .
– Install poly V-belt ⇒ page 41 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Assembly overview - battery .
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Install air filter housing ⇒ page 287 .
– Fit engine cover panel ⇒ page 38 .
– Check oil level.
– Connect coolant hoses.
– Add coolant ⇒ page 199 .
Note
Never reuse old coolant.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Removing and installing subframe without
steering rack .
– Adjust assembly mountings ⇒ page 36 .
– Install front wheel housing liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

- Edition 12.2017
Caution
Danger of destroying control units through excessive

swa
gvoltage
en AG. V
olkswagen AG
does
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♦ Never use battery charging equipmentsfor
ed boost starting.
by ara
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– After renewing engine, adapt the chain elongation. To do so,
ce
le
un
pt
select 01 - Chain elongation adaption diagnosis in
an
d
itte
Guided Functions ⇒ Vehicle diagnostic tester.
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Specified torques
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 29
ole,
spec
♦ ⇒ “2.1 Assembly overview - emission control”, page 338
t to the co
♦ ⇒ “1.1 Assembly overview - silencers”, page 329
♦ ⇒ “2.1 Assembly overview - air filter housing”, page 286
rrectne
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Specified torques for gearbox .
ss o
cial p
f inform
Note
mer
atio
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♦ The specified torques are only valid for nuts and bolts which
n
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have been slightly greased, oiled, phosphate-treated or black-
thi
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♦ Additional lubricant such as engine oil or gear oil may be used,

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but do not use lubricant containing graphite.

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♦ Do not use degreased parts.
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♦ Tolerance for specified torques ± 15%.
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Component Nm
Bolts and nuts M6 10
M7 15
M8 20
M10 40
M12 65

- Edition 12.2017
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 29
⇒ “2.2 Supporting engine in installation position”, page 31
⇒ “2.3 Removing and installing motor mounting”, page 34
⇒ “2.4 Removing and installing gearbox mounting”, page 34 AG. Volkswagen
n AG do
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⇒ “2.5 Removing and installing pendulum support”,y Vpage ot g
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⇒ “2.6 Checking adjustment of assembly mountings
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ris (engine and tee
or
gearbox mountings)”, page 36 s au ac
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⇒ “2.7 Adjusting assembly mountings”, page 36
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2.1 Assembly overview - assembly mountings
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1 - Bolt
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spec
❑ Renew after removal
❑ Specified torque and
t to the co
tightening sequence
⇒ page 50
rrectne
2 - Engine support
❑ Removing and installing
ss
⇒ page 49
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3 - Engine mounting
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❑ With support arm
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⇒ page 34
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❑ Renew after removal Prote AG.
❑ 20 Nm +90°
6 - Bolt
❑ 40 Nm +90°
7 - Bolt
❑ 60 Nm +90°
8 - Pendulum support
⇒ page 36
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 36
10 - Bolt
11 - Bolt
2. Assembly mountings 29
- Edition 12.2017
12 - Bolt
❑ 60 Nm +90°
13 - Bolt
❑ 60 Nm +90°
14 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ page 34
15 - Bolt
❑ 50 Nm +90°
AG. Volkswagen AG d
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- Edition 12.2017
2.2 Supporting engine in installation position

equipment required
AG. Volkswagen AG d
agen oes
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♦ Support - 10 - 222 A- cop Vo
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♦ Adapter - 10 - 222 A /18-
AG.
♦ Adapter - 10 - 222 A /29-

♦ -T40091/1- and -T40091/3- from engine support basic set -
T40091-
- Edition 12.2017
♦ -T40093/3- and -T40093/3-6- from engine support supplement

set - T40093-
♦ Hook - 10 - 222 A /20-
Preparing tools
– If adapter -10 - 222 A /4- does not yet have the hole -arrow-,
it must now be drilled into it.
• Dimension -a- = 225 mm.
• Hole diam. = 12.5 mm.
– Release catch -arrow- and detach mounting -1- for engine

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– Unclip right mounting -1- for engine cover panel from retainer
-2-.
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– On both sides of vehicle, insert adapter - 10 - 222 A /29- be‐ C py
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tween upper wheel housing longitudinal member and under‐
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cop Vo
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♦ Installation position:
“L” = -1-: adapter is to be inserted on right side of vehicle ( adapter
is engaged in recess of wing).
“R” (not shown in figure), adapter is to be inserted on left side of

vehicle.
Arrow -2- always points in direction of travel.

- Edition 12.2017
– Push adapter - 10 - 222 A /18- and two connecting pieces -

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T40091/3- onto support bracket - 10-222 wage.n AG
A- does
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– Secure support bracket - 10-222 eA-
d b to adapters - 10 - 222 A / ran
ris
29- . ut
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– Remove upper part of washers fluid reservoir ⇒ Electrical sys‐
ce
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tem; Rep. gr. 92 ; Windscreen washer system; Removing and
nl
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installing washer fluid reservoir .
itte
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– If present, pull off wires in front area of flange on both longi‐
ercia
o
tudinal members -arrow-. Do not disconnect pipe/hose sys‐
rm
m
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c
– Place adapters - T40093/3-6- onto both longitudinal members

or
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(the figure shows the right longitudinal member).

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– If necessary, carefully unclip any pipes for air conditioning
o
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system in front area. Do not disconnect pipe/hose system ⇒

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Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Cop py
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System overview - refrigerant circuit . rig ht
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• Each of the adapters - T40093/3-6- locks with pin -A- behind Prote
cted AG.
agen
the web of the longitudinal member -arrow-.
– Bolt on spindles - T40093 /3- .

– Connect spindles - T40093 /3- to support bracket - T40091/1-
using square tubes - 10-222 A- , and tighten.
– Then hook spindles into lifting eyes of engine, using hook - 10
- 222 A /20- and, if necessary, shackle - 10 - 222 A /12- .
– Take up weight of engine/gearbox assembly and support
bracket on spindles .
- Edition 12.2017
2.3 Removing and installing motor mounting

Removing
– Free hoses -2- from fittings and lay them to one side.
– Using a screwdriver, release catches -arrow-. Lay coolant ex‐
pansion tank to one side.
– Support engine in its installation position ⇒ page 31 .
– Take up weight of engine/gearbox assembly slightly with spin‐
dle; do not lift.
– Unscrew bolts -arrows- and remove engine mounting -1-.

Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ page 36 .
Specified torques
2.4 Removing and installing gearbox

mounting
Removing
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Removing and installing battery tray . d byV ua
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ris tee
– Remove engine control unit - J623- from bracket (lines
ut
ho remain or
connected) ⇒ page 325 . ss
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– Unscrew nuts -arrows- and remove bracket -1-.

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Different types of brackets are fitted depending on version.

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34
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Prote AG.
Rep. gr.10 - Removing and installing engine
- Edition 12.2017
– Unclip wire guide -1- upwards -arrows-, and push it slightly to

one side.
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– Unscrew bolts -2-. Then unscrew bolts -arrows-, and remove
rrectness of i
gearbox mounting -1-.
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Installing
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Note
on
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Renew bolts that are tightened with turning further angle.

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– Tighten gearbox mounting on longitudinal member.

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Caution
p by
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Prote AG.
Risk of damage to threads in the gearbox support by starting
bolts at an angle.
♦ Gearbox support and support arm of gearbox mounting
must be perfectly parallel to each other before screwing in
bolts. If necessary, lift gearbox at rear using trolley jack.
♦ Do not remove support bracket - 10 - 222 A- until the bolts
securing the assembly mounting have been tightened to
specified torque.
– Lift gearbox with spindle of support bracket until gearbox sup‐

port makes contact with support arm of gearbox mounting.
– Checking adjustment of assembly mountings ⇒ page 36 .
– Remove support bracket - 10 - 222 A- from engine.
Specified torques
♦ Battery; Assembly overview - battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Assembly overview - battery
- Edition 12.2017
2.5 Removing and installing pendulum sup‐

port
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unscrew bolts -1, 2 and 3-, and remove pendulum support.
Installing
Specified torques
Stage Bolts Specified torque/turning further angle
1. -2 and 3- 50 Nm
2. -1- 130 Nm
3. -1 … 3- Turn 90° further
♦ Noise insulation; Assembly overview - noise insulation ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation
2.6 Checking adjustment of assembly

mountings (engine and gearbox mount‐
ings)
AG. Volkswagen AG d
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The following specifications must be obtained:rised ara
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• There must be a distance of -a- = 10 mm aut between engine ra
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support -2- and engine mounting -1-.
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• Side surface of the engine support casting should be located

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• Distance -b- = distance -b-.

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

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

mountings ⇒ page 36 .
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2.7 Adjusting assembly mountings

nform
mercia
Procedure
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for
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Cop py
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Prote AG.

- Edition 12.2017
– Unscrew engine mounting bolts -arrows- one after the other

and renew them (if not already renewed when installing en‐
gine).
– First screw bolts in loosely.
– Using assembly lever, adjust engine/gearbox assembly until

specifications listed below are attained:
• There must be a distance of -a- = 10 mm between engine
support -2- and engine mounting -1-. AG. Volkswagen AG d
agen oes
olksw not
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• Side surface of the engine support casting should be slocated
d by ara
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parallel to support arm of engine mounting. thor eo
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• Distance -b- = distance -b-. ss
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Note
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Check distance -a- = 10 mm using, for example, a suitable rod.
, is n
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spec
– Tighten bolts for engine mounting.
es, in part or in w
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– Unscrew gearbox mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐
rrectness of i
gine).
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– First screw bolts in loosely.
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• Distance -x- = distance -x-.
agen
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– Tighten bolts for gearbox mounting.

Specified torques
♦ ⇒ Electrical system; Rep. gr. 27 ; Battery; Assembly overview
- battery
- Edition 12.2017
3 Motor cover
⇒ “3.1 Removing and installing engine cover”, page 38
3.1 Removing and installing engine cover

Removing
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Do not pull off motor cover panel abruptly or only onthone
or side. eo
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– Carefully pull engine cover panel off the four retaining pins
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-arrows- one after the other.
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Installing
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– To avoid damage, do not strike the engine cover panel with
spec
your fist or with any kind of tool.
es, in part or in w
t to the co
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
rrectness of i
– Press engine cover panel into rubber grommets first on left
side and then on right side.
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Prote AG.

- Edition 12.2017
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”,
page 39
⇒ “1.2 Removing and installing poly-V belt”, page 41
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 42
⇒ “1.4 Removing and installing bracket for ancillaries”,
page 42
⇒ “1.5 Removing and installing vibration damper”, page 44
⇒ “1.6 Removing and installing engine support”, page 49
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 50
1.1 Assembly overview - cylinder block (pulley end)
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Poly V-belt routing
⇒ page 41
⇒ page 41
❑ When installing, make
sure it is properly seated
on pulleys. AG. Volkswagen AG d
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2 - Tensioning device for poly byV
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spanner to slacken poly s
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V-belt.
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❑ Lock with locking pin -

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T10060 A- .
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⇒ page 42
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spec
3 - Bolt
t to the co

❑ 8 Nm +45°
rrectne
4 - Bolt
ss
❑ Moisten O-ring with oil.

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❑ Use counter-hold tool -

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1. Cylinder block (pulley end) 39

- Edition 12.2017
6 - Vibration damper
❑ With poly V-belt pulley
7 - Ancillary bracket
❑ With oil filter and engine oil cooler
❑ Removing and installing ancillary bracket ⇒ page 42 .
❑ Removing and installing engine oil cooler ⇒ page 179
8 - Seal
9 - Bolt
10 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
11 - Alternator
❑ Assembly overview ⇒ Electrical system; Rep. gr. 27 ; Alternator; Assembly overview - alternator
12 - Dowel sleeves
❑ For air conditioner compressor. agen
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❑ Do not unscrew or disconnect refrigerant lines
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❑ Assembly overview ⇒ Heating, air conditioning;
ss Rep. gr. 87 ; Air conditioner compressor; Assembly c
overview - drive unit of air conditioner compressor .
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❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐
ility
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Ancillary bracket - specified torques and tightening sequence
t to the co
– Fit bracket for ancillaries (first tighten bolt -4- by hand).
Note rrectness of i
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– Tighten bolts in sequence -1 … 5- in 3 stages as follows:

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1. Tighten bolts by hand.

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2. Tighten bolts to 20 Nm.

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3. Turn bolts 90° further.

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40 Rep. gr.13 - Crankshaft group

- Edition 12.2017
Poly V-belt routing

1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
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1.2 Removing and installing poly-V belt
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♦ Locking pin - T10060 A-
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spec
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– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr. copy Vo
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Prote AG.
washer fluid reservoir .
Caution
If a used poly V-belt runs in the opposite direction when it is

refitted, this can cause severe damage
♦ Before removing the poly V-belt, use a piece of chalk or a
felt pen to mark the running direction.
– To slacken poly V-belt turn tensioning device in direction of

-arrow-.
– Lock tensioning device in place with locking pin - T10060 A- .
– Remove poly V-belt.

- Edition 12.2017
Installing
Install in reverse order of removal. During this procedure, observe
the following:
– Fit poly V-belt as shown in figure.
1- Vibration damper AG. Volkswagen AG d
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2- Tensioning device for poly V-belt d byV gu
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3- Alternator ut
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4- Air conditioner compressor
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– Turn tensioning device in -direction of arrow-, and pull out
ot
locking pin - T10060 A- .
wit
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– Release tensioner.
spec
es, in part or in w
– Check that poly V-belt is properly seated.
t to the co
– Start engine and check that poly V-belt runs properly.
rrectness of i
Specified torques
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1.3 Removing and installing tensioner for
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– Remove poly V-belt ⇒ page 41 . Cop py
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– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr. py by
co Vo
92 ; Windscreen washer system; Removing and installing
by lksw
cted agen
Prote
AG.
– Unscrew bolts -arrows- and pull tensioning device -1- for poly
V-belt off ancillary bracket.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
39
1.4 Removing and installing bracket for an‐

cillaries
Removing
– Drain coolant ⇒ page 198 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove air conditioner compressor (with refrigerant lines con‐
nected) from bracket, and tie it up to right side ⇒ Air condi‐
tioning system; Rep. gr. 87 ; Air conditioner compressor;

- Edition 12.2017
Removing and installing air conditioner compressor from and

to bracket .
– Disconnect connectors -1, 2 and 3-.
– Remove oil filter element ⇒ Maintenance ; Booklet ; Engine
oil: Draining; Renewing oil filter and replenishing engine oil .
– Unclip retainer for wiring harness -2-. Remove bolt -1- for dip‐
stick guide tube.
– Unclip guide tube from timing chain cover
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– Move wiring harness clear. spec

es, in part or in w
t to the co
– Place drip tray - VAS 6208- beneath engine.
– Unscrew bolts -1 … 5- and detach bracket for ancillary units
rrectness of i
from coolant pump housing.

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Installing
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orm
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atio
Note
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♦ Renew bolts that are tightened with a turning further angle.

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♦ Renew O-rings and seals.

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Cop py
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pyri by
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co lksw
by
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Prote AG.

- Edition 12.2017
– Moisten new O-rings -4- with coolant.

– Insert connecting piece -2- into coolant pump housing -3-.
– Push engine oil cooler -1- onto connection. Start bolts, then
tighten them to specified torque ⇒ page 40 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Assembly overview
- drive unit of air conditioner compressor .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install oil filter and check oil level ⇒ Maintenance ; Booklet ;
Engine oil: Draining; Renewing oil filter and replenishing en‐
gine oil .
Specified torques
39
♦ ⇒ “1.1 Assembly overview - cover for timing chain”,
page 82
♦ Alternator; Assembly overview - alternator ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Alternator; Assembly overview - alternator .
1.5 Removing and installing vibration damp‐

er
♦ Counter-hold tool - T10355-
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♦ Assembly tool - T10531-

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♦ Support - T10531/1- Cop py
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44
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Prote AG.
Rep. gr.13 - Crankshaft group
- Edition 12.2017
♦ Clamping pin - T10531/2-

♦ Turning over tool - T10531/3-
♦ Collar nut - T10531/4-
The vibration damper securing bolt -A- is used to secure the vi‐
bration damper -1- and the timing chain sprocket -2-
AG. Voon crankshaft
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Removing
– Remove washer fluid reservoir ⇒ Electrical system; Rep. gr.
rrectness of i
l purpos
– Remove poly V-belt ⇒ page 41 .

– Pull locking pin - T10060 A- out of tensioning device for poly
nf
ercia
o
V-belt.
rm
m
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m
– Turn vibration damper to TDC position -arrow- using counter-

o
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c
hold tool - T10355- .

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• Notch on vibration damper must align with arrow marking on

iv
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cover for timing chains (bottom).

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• The marking on the cover is located at »4 o'clock position«.
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– Loosen vibration damper bolt by 1/2 turn using counter hold
p by
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tool - T10355- .
agen
Prote AG.
– If vibration damper was turned while loosening bolt, reset TDC

position.
– Unscrew bolts -arrows- for timing chain cover. Bolts must be

renewed.

- Edition 12.2017
– Fit support - T10531/1- to vibration damper, as shown in illus‐

tration, and tighten knurled screws -arrows- by hand.
– Unscrew vibration damper bolt completely.
– Check if turning over tool -A- slides easily over clamping

pieces -B-. If necessary, turn tensioning bolt -arrow-.
Note
Do not turn the tensioning bolt any more, otherwise the clamping
pin - T10531/2- will be jammed when it is screwed into the crank‐
shaft.
– Screw clamping pin - T10531/2- into crankshaft, and tighten it

hand-tight with a 12 mm open-end spanner -A-.
AG. Volkswagen AG d
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– Tighten tensioning bolt -A- by hand in order to lock the chain

h re
ole,
sprocket in position relative to crankshaft.

spec
t to the co
rrectness o
cial p
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Cop py
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cted agen
Prote AG.

- Edition 12.2017
– Unscrew knurled screws -arrows-.

– Remove support - T10531/1- and vibration damper -A-.
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Turning crankshaft without vibration damper
un
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– Fit turning over tool -A- on clamping pin. Pay attention to tooth‐
rm
ab
ed contours of chain sprocket while doing so. In TDC position
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the flat section of the tool faces upwards.
wit
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– Tighten turning over tool with flange nut -B-.
hole
spec
es, in part or in w
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– Now, the crankshaft can be turned on hexagon -arrow-.
nform
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r
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Prote AG.
Installing
– If necessary, remove flange nut -B- and turning over tool -A-
from clamping pin.

- Edition 12.2017
– Fit vibration damper in TDC position. Pay attention to teeth of

chain sprocket -arrow- while doing so.
– Fit turning over tool -A- on clamping pin. The hexagon faces
towards vibration damper while doing so.
– Screw on flange nut -B-. Move vibration damper slightly back
and forth while doing so, in order to ensure that vibration
damper is properly seated on teeth.
– Tighten flange nut, until vibration damper cannot be turned any
more.
– Fit support - T10531/1- to vibration damper, as shown in illus‐

tration, and tighten knurled screws -arrows- by hand.
AG. Volkswagen AG d
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spec
– Unscrew flange nut -A-, and loosen clamping pin -B-.

es, in part or in w
t to the co
– Unscrew clamping pin , and remove it together with turning

over tool .
rrectness of i
l purpos
nform
mercia
at
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ion
c
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ate
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for
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.

- Edition 12.2017
– Screw in new vibration damper bolt with lubricated O-ring -1-

by hand.
– Unscrew knurled screws -arrows-, and remove support -

T10531/1- .
AG. Volkswagen AG d
agen oes
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– Tighten vibration damper bolt using counter hold tool -

hole
spec
T10355- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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– Screw in new bolts -arrows-.

a
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Specified torques
f
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t.
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1.6 Removing and installing engine support

Removing
– Removing engine mounting ⇒ page 34 .

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d ara III) Volkswagen R GmbH
nte
- Edition 12.2017 autho eo
ra
ss c
ce
le
– Raise engine by dimension -a- using spindle - 10 - 222 A /11-
un
pt
-item 1-.
an
d
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• Dimension -a- = about 30 mm.
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– Unscrew bolts -1, 2 and 3-, and remove engine support.
nform
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Installing
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– Install engine mounting ⇒ page 34 .
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Engine support - specified torque and installation sequence
Note
Renew bolts.
– Tighten bolts in stages in the sequence shown.

Stage Bolts Specified torque/turning further angle
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- Turn 90° further
1.7 Renewing crankshaft oil seal - belt pul‐

ley end
♦ Thrust piece - T10354-

- Edition 12.2017
♦ Thrust plate - T10375-
♦ Flange nut - 10531/4- from assembly tool - T10531-
♦ Extractor hook - T40274-
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Removing
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– Remove vibration damper ⇒ page 44 .

ility
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• Clamping pin - T10531/2- is inserted.

h re
hole
spec
– Using extractor hook - T40274- , pull out seal -arrow-.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
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ate
do
priv
cum
for
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t.
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Cop py
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pyri by
51
co Vo
by lksw
cted 1. Cylinder block (pulley end)
agen
Prote AG.
- Edition 12.2017
Installing
– Clean contact surface and sealing surface.
– Slide seal -arrow- onto thrust piece - T10354- .
• Closed side of oil seal faces towards thrust piece - T10354- .
– Slide seal -arrow- with thrust piece - T10354- onto clamping

pin - T10531/2- , and fit it to lower timing chain cover.
AG. Volkswagen AG d
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un
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– In addition, fit thrust pad - T10375- , and screw on flange nut
pe
ility
- 10531/4- .
ot
wit
, is n
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– Using a 21 mm open-end spanner, tighten flange nut until seal
hole
has been pressed in to stop.
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Renew bolt for vibration damper.
l purpos
♦ Renew O-ring.
nform
ercia
– Install vibration damper ⇒ page 44 .

m
a
Specified torques
com
tion in
r
te o
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39
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Prote AG.

- Edition 12.2017
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 53
⇒ “2.2 Removing and installing flywheel”, page 54
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 55
2.1 Assembly overview - cylinder block, gearbox end
1 - Flywheel
❑ Can be installed only in
one position - bores are
offset
⇒ page 54
2 - Dowel sleeve
3 - Sealing flange, gearbox
side
❑ With seal
⇒ page 55 n AG. Volkswagen AG do
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❑ Do not oil or grease oil yV
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seal sealing lip. ir se
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❑ Before installing, re‐ auth or
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move oil residue from ss ce
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crankshaft journal using

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pt
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a clean cloth.
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❑ Do not remove guide

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sleeve until sealing

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flange has been slid on‐

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to crankshaft journal.
hole
spec
4 - Cylinder block
es, in part or in w
t to the co
5 - Bolts
❑ Observe tightening se‐
rrectness of i
quence ⇒ page 54
❑ 9 Nm
l purpos
6 - Adapter
nform
ercia
❑ Illustration does not

show version installed in
m
at
vehicle.
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❑ Must seat on dowel

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sleeves.
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❑ Do not damage or bend when assembling.

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❑ Is fitted onto sealing flange ⇒ page 54

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8 - Bolts
c by lksw
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Prote AG.
❑ For dual-mass flywheel
❑ 60 Nm +90°
2. Cylinder block, gearbox end 53

- Edition 12.2017
Install intermediate plate.

– Engage intermediate plate on sealing flange, and press onto
dowel sleeves -arrows-.
Sealing flange at gearbox end - tightening sequence AG. Volkswagen AG d

agen oes
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– Tighten bolts -1 to 8- in the sequence shown. ised b ara
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2.2 Removing and installing flywheel
rrectness of i
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♦ Counter-hold tool - 3067-
nform
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tion in
r
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Cop py
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Prote AG.
Removing
• Gearbox is removed.
Caution
Risk of severe damage to the flywheel

♦ Screw out bolts -B- not with an air wrench or power impact
wrench but by hand.
♦ When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.
♦ Rotate dual-mass flywheel -A- so that bolts -B- align cen‐
trally with the holes -arrows-.

- Edition 12.2017
– Insert counterhold tool - 3067- in hole -B- in cylinder block.

– Loosen and remove flywheel bolts.
Installing
AG. Volkswagen AG d
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hbolts that are tightened with turning further angle.
or eo
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– Insert counterhold tool - 3067- in hole -A- of cylinder block.
erm
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Specified torques
wit
, is n
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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
hole
spec
53
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
2.3 Removing and installing sealing flange

m
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on gearbox side
n in
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⇒ “2.3.1 Distinguishing features for sealing flange, gearbox side”,

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page 55
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⇒ “2.3.2 Removing and installing sealing flange on gearbox side,
Co
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version A sealing lip faces outwards”, page 56
. C rig
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⇒ “2.3.3 Removing and installing sealing flange on gearbox side,
co Vo
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version B sealing lip faces engine”, page 58
Prote AG.
2.3.1 Distinguishing features for sealing

flange, gearbox side
Differentiating criteria
Note
There are 2 versions of the sealing flange.
– Check which version must be installed.

♦ Version A: sealing lip -1- faces gearbox (outwards).
♦ Version B: sealing lip -1- faces engine. This sealing flange also
has a dust lip -2-.
– Removing and installing version A ⇒ page 56 .
– Removing and installing version B ⇒ page 58 .

- Edition 12.2017
2.3.2 Removing and installing sealing flange

on gearbox side, version A sealing lip
faces outwards
AG. Volkswagen AG d
agen
♦ Assembly sleeve - T20097- Volksw
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♦ Hand drill with plastic brush attachment
rrectness of i
♦ Safety glasses
l purpos
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
nform
ercia
Removing
m
a
– Remove flywheel ⇒ page 54 .
com
tion in
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– Detach intermediate plate from sealing flange and dowel pins

te o
thi
-arrows-.
s
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Prote AG.
– Unscrew bolts -1 to 8-.

– Remove sealing flange.

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ho chain drive, generation III) Volkswagen e oR GmbH
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ss - Edition 12.2017
c
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Installing
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Note
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♦ Observe use-by date of silicone sealant.
♦ Install the sealing flange within 5 minutes after application of
the silicone sealant.
rrectne
– In order to prevent the lubrication system from being soiled,
ss
cover the open section of the sump with a clean cloth.
o
cial p
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mer
WARNING
atio
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n
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Risk of eye injury.
or
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♦ Wear safety goggles.

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op
– Remove sealant residue.
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– Clean sealing surfaces. co Vo
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– Cut off nozzle on tube at front marking (∅ of nozzle approx.
AG.
2 mm).
– Apply silicone sealant -arrow- to clean sealing surface of seal‐

ing flange.
• Thickness of sealant bead: 2 to 3 mm.
– Clean crankshaft journal.

– Check assembly sleeve - T20097- ; it must be free of any de‐
formation or sharp edges.
– Fit assembly sleeve - T20097- onto crankshaft journal -A-.
– Fit sealing flange over assembly sleeve - T20097- onto crank‐
shaft journal.
– Remove assembly sleeve - T20097- .
– Tighten bolts; observe tightening sequence ⇒ page 54 .
• After installing the sealing flange, wait about 30 minutes for
the sealant to dry. Only then fill with engine oil.
Specified torques
53

- Edition 12.2017
2.3.3 Removing and installing sealing flange

on gearbox side, version B sealing lip
faces engine
♦ Guide piece - T10122/6- or guide piece - T10122/6A- from fit‐
ting tool - T10122B- or fitting tool - T10122C-
♦ Assembly aid - T10122/1- from fitting tool - T10122B- or fitting

tool - T10122C-

AG. Volkswagen A n G do
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♦ Safety glasses Volks ot g
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♦ Sealant ⇒ Electronicoris parts catalogue (ETKA) tee
th or
au ac
Removing ss
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un
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– Remove flywheel ⇒ page 54 .

an
d
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erm
– Detach intermediate plate from sealing flange and dowel pins

ab
ility
-arrows-.
ot p
wit
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spec
t to the co
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cial p
f inform
mer
atio
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c
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
58
Prote AG.
Rep. gr.13 - Crankshaft group
- Edition 12.2017

– Remove sealing flange.
Installing
– In order to prevent the lubrication system from being soiled,
cover the open section of the sump with a clean cloth.
WARNING
Risk of eye injury. agen

AG. Volkswagen AG d
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– Remove sealant residue. s
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– Clean sealing surfaces.

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Note
wit
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spec
Observe use-by date of silicone sealant.

es, in part or in w
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2 mm).
rrectness of i
– Apply silicone sealant -arrow- to clean sealing surface of seal‐

l purpos
ing flange.
nf
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Cop py
t. rig
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pyri by
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co lksw
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Prote AG.

- Edition 12.2017
Note
♦ Check sealing flange; it must be free of kinks and damage.

♦ The sealing lip must face engine following installation. Other‐
wise, oil leaks may occur.
♦ Install the sealing flange within 5 minutes after application of
the silicone sealant.
– Check guide - T10122/6- -B-; it must be clean and free of sharp

edges.
– Attach assembly aid - T10122/1- -A- to guide - T10122/6-
-B-.
– Push sealing flange -C-, with outer side leading, onto guide
piece - T10122/6- -B-.
– Remove assembly aid -A-. AG. Volkswagen AG d
agen oes
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– Put guide -A- with sealing flange -B- onto crankshaft journal.
rrectness of i
Note
l purpos
It is not necessary to tighten the bolts -arrows-.

nf
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or
– Push sealing flange -B- over guide -A- onto crankshaft journal.
m
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– Remove guide -A-.

n in
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– Tighten bolts; observe tightening sequence ⇒ page 54 .

t
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• After installing the sealing flange, wait about 30 minutes for

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the sealant to dry. Only then fill with engine oil.

t.
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Specified torques
. C rig
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rig by
py Vo
co lksw
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53 Prote AG.

- Edition 12.2017
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 61
⇒ “3.2 Removing and installing sender wheel”, page 62
⇒ “3.3 Renewing needle bearing in crankshaft”, page 63
⇒ “3.4 Allocation of main bearing shells”, page 65
⇒ “3.5 Crankshaft dimensions”, page 66
⇒ “3.6 Measuring axial clearance of crankshaft”, page 67
⇒ “3.7 Measuring radial clearance of crankshaft”, page 67
3.1 Assembly overview - crankshaft
Note
Secure engine to repair stand using engine and gearbox support

- VAS 6095- when dismantling/assembling engine ⇒ page 23 .
1 - Cylinder block
G. Volkswagen AG d
2 - Bearing shell for cylinder lksw
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❑ With oil groove. thoris nte
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❑ Moisten with oil. au ra
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❑ Do not interchange
nl
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used bearing shells

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(mark).
erm
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❑ Marking of crankshaft
ot p
bearing shells (classifi‐ wit

, is n
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cation) ⇒ page 65
hole
spec
3 - Crankshaft
es, in part or in w
t to the co
❑ After removing, place it

down so that the sender
wheel
rrectness of i
⇒ Item 8 (page 62) is

not damaged and the
l purpos
crankshaft does not rest

on the sender wheel
nform
ercia
❑ If the crankshaft is re‐

newed, the bearing
m
at
om
shells must be reas‐

ion
c
signed to bearing cap

in t
or
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⇒ page 65 .
at
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❑ Axial clearance
p
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⇒ page 67
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❑ Radial clearance . Cop py
⇒ page 67
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❑ Do not rotate crankshaft
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when checking radial Prote AG.
clearance
❑ Crankshaft dimensions
⇒ page 66 .
4 - Bearing shell for bearing
cap
❑ Without oil groove.
❑ Moisten with oil.
3. Crankshaft 61
- Edition 12.2017
❑ Do not interchange used bearing shells (mark).
❑ Marking of crankshaft bearing shells (classification) ⇒ page 65
5 - Bolt
❑ Tightening sequence ⇒ page 62
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
7 - Bolt
❑ Sender wheel must be renewed if bolts are loosened ⇒ page 62
❑ 10 Nm +90°
8 - Sender wheel
❑ For engine speed sender - G28-
❑ Can be installed only in one position - bores are offset
❑ Always renew sender wheel if securing bolts have been unscrewed
9 - Thrust washers
❑ For bearing 3 lkswage es n
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❑ Moisten with oil.
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10 - Bolt ss
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Crankshaft tightening sequence

h re
hole
spec
– Tighten crankshaft bolts in the sequence -1 … 5- as follows:

es, in part or in w
t to the co
1. Tighten bolts -1 … 10- and -arrows A- by hand.

2. Tighten bolts -1 … 10- initially to 65 Nm.
rrectness of i
3. Turn bolts -1 … 10- 90° further using a rigid wrench.

l purpos
4. Tighten bolts -arrows A- initially to 20 Nm.

5. Turn bolts -arrows A- 90° further using a rigid wrench.
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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for
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Cop py
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pyri by
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by
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Prote
3.2 Removing and installing sender wheel
AG.
– Remove engine.
– Remove sealing flange on gearbox side ⇒ page 55 .
– Remove upper part of sump ⇒ page 174 .
– Remove balancer shaft timing chain ⇒ page 107 .
– Unscrew conrod bearing cap.

- Edition 12.2017
– Remove crankshaft bearing cap.

– Remove crankshaft and unscrew sender wheel.
– Renew sender wheel -2- each time bolts -1- are loosened.
Note
♦ The second time the bolts are tightened, the contact points in
the sender wheel for the countersunk heads are deformed so
much that the bolt heads seat on the crankshaft -3-, -arrows-
and the sender wheel is loose under the bolts.
♦ The sender wheel can only be installed in one position, the
holes are offset.
Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 61
3.3 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
♦ Counter support, e.g. KUKKO
Volkswa
22-1 - VAS 251 621-
AG. gen AG
agen does
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♦ Internal puller - VAS 251 635-

rrectness o
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f inform
mer
atio
om
n
c
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or
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Cop py
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by c lksw
cted agen
Prote AG.
3. Crankshaft 63
- Edition 12.2017
♦ Drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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Note
un
pt
an
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Always renew needle bearing -arrow- when separating engine
erm
ab
ility
and gearbox.
ot p
wit
is n
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spec
t to the co
rrectnes
Removing
s o
cial p
f
• Gearbox has been removed.
inform
mer
– Position internal puller - VAS 251 635- -A- behind needle
atio
m
bearing -arrow-.
o
n
c
i
or
– Pull out needle bearing -1- with internal puller - VAS 251 635- n thi
te
sd
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-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
iv
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pr
-B- from crankshaft -2- in -direction of arrow-.

um
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

- Edition 12.2017
Installing
– Clean bearing seat in crankshaft.
– Coat bearing seat with high-temperature paste ⇒ Electronic
parts catalogue (ETKA) .
– Drive in needle bearing to installation depth using mandrel -
VW 207 C- in -direction of arrow-.
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Installation depth: dimension -a- = 2.0 mm.
rrectne
Note
s
If the needle bearing has been driven in too far, it must be re‐
s o
cial p
newed, because it will be damaged when it is pulled out.
f inform
mer
atio
om
n
c
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or
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.4 Allocation of main bearing shells

Bearing shells of the correct thickness are allocated to the cylin‐
der block at the factory. Coloured dots are used to identify the
thickness of the bearing shells.
Which bearing shell is to be inserted at each place in the cylinder
block (upper bearing shell) is marked by letters on the lower seal‐
ing surface or on the front side of cylinder block.
Which bearing shell is to be inserted at each place in bearing cap
(lower bearing shell) is marked by letters on the crankshaft.
The first letter is allocated to bearing cap one, the second to bear‐
ing cap two, etc.
3. Crankshaft 65
- Edition 12.2017
Marking on bearing shell for cylinder block:
Note
The marking on the cylinder block can be found engraved either

in the sump sealing surface or in the front end (gearbox side) of AG. Volkswagen AG d
the cylinder block. lksw
agen oes
not
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ab
Identification on cylinder block is allocated to upper bearing shell
ility
ot p
(bearing shell for cylinder block).
wit
, is n
– Note letters and identify colour code to be installed based on
h re
hole
table.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Marking on bearing shell for bearing cap:
ht
pyri by
Vo
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by c lksw
Identification on crankshaft is allocated to lower bearing shell
cted agen
Prote AG.
(bearing shell for bearing cap).
– Note letters and identify colour code to be installed based on
table.
S = black
R = red
G = yellow
B = blue
W = white
3.5 Crankshaft dimensions

(Dimensions in mm)
Honing dimension Main journal ∅ Conrod journal ∅
1)
Basic dimension 58.00 47.80

- Edition 12.2017
1)No provision has yet been made to recondition worn crank‐

shafts.
3.6 Measuring axial clearance of crankshaft

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
. Volkswagen AG
gen AG does
swa
Procedure y Volk not
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– Screw dial gauge
thoris
- VAS 6079- with universal dial gauge holder
eo
- VW 387-
s auonto cylinder block and set against crank web with
ra
c
s
projection of approx. 2 mm.
ce
le
un
pt
– Press crankshaft against dial gauge by hand and set gauge to

an
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itte
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“0”.
rm
ab
pe
ility
– Push crankshaft away from dial gauge and read off value.
ot
wit
, is n
h re
Axial clearance:
hole
spec
• New: 0.070 ... 0.231 mm

es, in part or in w
t to the co
• Wear limit: 0.30 mm

rrectness of i
3.7 Measuring radial clearance of crank‐

shaft
l purpos

nform
ercia
♦ Plastigage
m
a
com
tio
Procedure
n in
r
te o
thi
s
iva
do
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Note
rp
cum
fo
en
ng
t.
yi Co
♦ Do not interchange used bearings. t. Cop py
rig
gh ht
♦ Bearing shells worn down to nickel layer must be renewed. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Crankshaft 67
- Edition 12.2017
– Remove crankshaft bearing cap, and clean bearing cap and

bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shells.
• The Plastigage must rest in the middle of the bearing shell.
– Fit crankshaft bearing cap, and tighten it to 1 Nm using old
bolts -1 to 10- ⇒ page 62 . Make sure not to rotate crankshaft
while tightening.
Note
Disregard bolts -arrows A-.
– Remove crankshaft bearing cap again.

– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.017 to 0.037 mm
• Wear limit: 0.15 mm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

- Edition 12.2017
4 Balancer shaft
⇒ “4.1 Assembly overview - balance shaft”, page 69
⇒ “4.2 Removing and installing balance shaft”, page 70
AG. Volkswagen AG d
⇒ “4.3 Renewing oil seal for balance shaft (inlet side)”, agen oes
olksw not
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page 74 d by gu
ara
rise nte
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4.1 Assembly overview - balance shaft th
au ra
ss c
ce
le
un
pt
an
d
1 - Bolt
itte
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erm
ab
ility
ot p
❑ 4 Nm +45°
wit
is n
h re
ole,
2 - Balancer shaft
spec
❑ Exhaust side
t to the co
❑ Must always be re‐
newed if removed.
❑ Lubricate bearing with
rrectne
engine oil
❑ Renewing ⇒ page 72
ss o
cial p
f
3 - Gear ring for needle bearing
inform
mer
atio
om
plied with balance shaft.
n
c
i
or
n thi
e
4 - Tube for balancer shaft

t
sd
iva
o
pr
c
❑ Fitting position
um
r
fo
⇒ page 70
en
ng
t.
yi Co
op py
5 - Cylinder block t. C rig
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pyri by
6 - Oil seal for balance shaft,
co Vo
by lksw
cted
inlet side
agen
Prote AG.
7 - Balancer shaft
❑ Inlet side
newed if removed.
❑ Lubricate bearing with
engine oil
8 - Gear ring for needle bearing
plied with balance shaft.
9 - Bolt
❑ 4 Nm +45°
4. Balancer shaft 69
- Edition 12.2017
Tube for balancer shaft - installation position

The apertures -arrow- must face towards chain side.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
4.2 Removing and installing balance shaft
, is n
h re
hole
spec
⇒ “4.2.1 Removing and installing inlet side balance shaft”,
es, in part or in w
page 70
t to the co
⇒ “4.2.2 Removing and installing exhaust side balance shaft”,
page 72
rrectness of i
4.2.1 Removing and installing inlet side bal‐
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– Remove toothed belt for coolant pump ⇒ page 231 .

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– Remove timing chain cover (top) ⇒ page 84 .

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– Remove lower timing chain cover ⇒ page 86 .

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– Remove camshaft timing chain ⇒ page 94 . C py
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– Remove drive chain for balance shafts ⇒ page 107 . cop Vo
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– Unscrew bolt -2-.
AG.
– Detach drive sprocket -1- for toothed belt for coolant pump.

- Edition 12.2017
– Remove intermediate shaft sprocket -1-.
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– Unscrew bolt -2- for balance shaft on inlet side, and pull out
es, in part or in w
balance shaft.
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yi Co
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– Install balance shaft for inlet side and tighten bolt -2-.
- Edition 12.2017
– Renew O-ring -1- and lubricate with engine oil.

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The idler gear must always be renewed. Otherwise no tooth
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The new idler gear is coated with a solid film lubricant that
hole
wears off after a short period and thus automatically sets the
spec
es, in part or in w
tooth backlash.
t to the co
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– Mark faces of gear teeth of idler gear with paint -arrow-.
l purpos
– Insert idler gear; marking on balance shaft must be positioned

between markings on faces of gear teeth.
nform
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– Tighten bolt -1- for idler gear; tightening sequence
by lksw
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⇒ page 93 .
AG.
– Check markings on idler gear/balance shaft -arrow-.

Further installation is carried out in reverse order of removal, ob‐
serving the following:
– Install drive chain for balance shafts ⇒ page 107 .
– Install camshaft timing chain ⇒ page 94 .
– Install timing chain cover (bottom) ⇒ page 86 .
– Install timing chain cover (top) ⇒ page 84 .
– Renew oil seal for balance shaft on inlet side ⇒ page 74 .
– Fit toothed belt for coolant pump ⇒ page 231 .
Specified torques
♦ ⇒ “4.1 Assembly overview - balance shaft”, page 69
4.2.2 Removing and installing exhaust side

balance shaft
Removing
• Engine is removed.
– Remove camshaft timing chain ⇒ page 94 .
– Remove drive chain for balance shafts ⇒ page 107 .

- Edition 12.2017
– Unscrew bolt -1- for balance shaft on exhaust side, and pull
out balance shaft.
Installing n AG. Volkswagen AG do

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d b position of tube for balance shaft.uaThe
ran aper‐
tures -arrow-
tho must face towards chain side.
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– Lubricate bearing points of balance shaft -arrows- with engine

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- Edition 12.2017
– Install balance shaft for exhaust side.

– Before tightening bolt -1-, check if balance shaft rests flat
against crankcase.
Note
If the balancer shaft does not rest flat, the pipe for balancer shaft
must be inserted again.
Further installation is carried out in reverse order of removal, ob‐

serving the following:
– Install drive chain for balance shafts ⇒ page 107 .
Specified torques
♦ ⇒ “4.1 Assembly overview - balance shaft”, page 69
4.3 Renewing oil seal for balance shaft (inlet

side)
AG. Volkswagen AG d
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Procedure
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– Detach drive sprocket -1- for toothed belt for coolant pump.
m
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Cop py
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Prote AG.

- Edition 12.2017
– Press screwdriver -1- firmly onto section -2- of oil seal

-arrow B-.
– Lever out oil seal -arrow A-.
– Clean contact surface andolksealing
en AG. V
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– Lubricate sealing surface of balance shaft -2- with gear oil.
h re
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– Fit oil seal -1- onto balance shaft.
t to the co
• The marking “Luftseite” (or “Outside”) -arrow- should be legi‐
ble from the outside.
rrectness o
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Risk of damage to the thread
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♦ The drive sprocket bolt has a left-hand thread.
p by
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– Apply thrust piece - T10353/1- to oil seal -1- and press into
cylinder block as far as stop using bolt -2- (take care not to tilt
oil seal).
– Fit toothed belt for coolant pump ⇒ page 231 .
- Edition 12.2017
AG. Volkswagen AG d
agen oes
5 Pistons and conrods d by
Volksw not
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⇒ “5.1 Assembly overview -utpistons and conrods”, page 76
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⇒ “5.2 Removing and installing pistons”, page 77
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⇒ “5.3 Separating new conrod”, page 79
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⇒ “5.4 Checking pistons and cylinder bores”, page 79
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5.1 Assembly overview - pistons and conrods
spec
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1 - Conrod bolts
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❑ Oil threads and contact
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❑ Use old bolt for measur‐
nform
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ing radial clearance.

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❑ 45 Nm +90°
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2 - Conrod bearing cap
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❑ Observe installation po‐
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rig
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priate conrod due to the op Vo
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to separate the cap from
the conrod.
❑ Mark with cylinder num‐
ber -A-.
❑ Installation position:
Marking -B- faces to‐
wards pulley end.
❑ Separate new conrod
⇒ page 79 .
3 - Bearing bushes
⇒ page 77
used bearing shells
(mark).
❑ Moisten with oil before
installing.
❑ Axial clearance, new:
0.10 to 0.35 mm, wear
limit: 0.40 mm
❑ Measure radial clearance using Plastigage; new: 0.02 to 0.06 mm; wear limit: 0.09 mm. Do not turn
crankshaft when measuring radial clearance.
4 - Pressure relief valve
❑ 27 Nm
5 - Oil spray jet
❑ For piston cooling
6 - Retaining ring

- Edition 12.2017
7 - Piston pin
❑ Moisten with oil before installing.
8 - Piston
❑ Mark installation position and cylinder number.
❑ Arrow on piston crown points to belt pulley end.
❑ Checking piston and cylinder bore ⇒ page 79
9 - Compression rings
❑ Use commercially available piston ring pliers to remove and install.
❑ Offset gaps by 120°
❑ Installation position: “TOP” or “R” marking must face upwards towards piston crown.
❑ Checking ring gap ⇒ page 80 .
❑ Checking ring-to-groove clearance ⇒ page 80 .
10 - Oil scraper ring
❑ Two-piece design.
❑ Install such that gap is offset 120° relative to adjacent compression ring.
❑ “TOP” or “R” marking must face upwards towards piston agencrown.
AG. Volkswagen AG d
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❑ Ring-to-groove clearance not measurable. thori
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❑ Installation position: Marking -B- faces towards pulley end.
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❑ Measuring radial clearance ⇒ page 81
spec
t to the co
Bearing shells - installation position
rrectne
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
ss
Distance -a- must be identical on both sides.
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Special tools and workshop equipment required cted agen
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5. Pistons and conrods 77

- Edition 12.2017
♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
– Secure engine on engine and gearbox support - VAS 6095-
⇒ page 23 .
– Remove cylinder head ⇒ page 115 .
– Remove upper part of sump ⇒ page 174 .
– Mark piston installation position and corresponding cylinder
number.
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 11 (page 77) .
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
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– Drive out piston pin using drift - VW 222 A- .

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♦ Offset piston ring gaps by 120°.

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– Oil running surfaces of bearing shells.

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– Install piston with commercially available piston ring clamp,

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noting installation position ⇒ Item 8 (page 77) .

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⇒ Item 2 (page 76) . t. Cop py
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– Install cylinder head ⇒ page 115 . yri
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– Install upper part of sump ⇒ page 174 .
agen
Prote AG.
Specified torques
♦ ⇒ “5.1 Assembly overview - pistons and conrods”, page 76

- Edition 12.2017
5.3 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark the cylinder to which the conrod belongs
⇒ Item 11 (page 77) .
– Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

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

ing cap in -direction of arrow- until it is loose.
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5.4 Checking pistons and cylinder bores
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♦ Micrometre 75 - 100 mm - VAS 6071-

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Checking piston
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– Using a micrometer, measure approx. 15 mm from the lower

h re
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edge, perpendicular to the piston pin axis.

spec
es, in part or in w
♦ Difference between actual and nominal diameter max.

t to the co
0.04 mm.
Piston ∅
rrectness of i
Basic dimension mm 82.4201)

l purpos
• 1)
Dimensions without graphite coating (thickness 0.02
mm). The graphite coating will wear down.
nform
mercia
a
com
tion in
r
te o
thi
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cum
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

- Edition 12.2017

♦ Feeler gauge
Checking piston ring gap
– Push piston ring at right angles to cylinder wall from above
down to approx. 15 mm from bottom end of cylinder. Push in
using a piston without rings.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.30 … 0.40 0.80
2nd compression ring 0.40 … 0.50 0.80
Oil scraper ring 0.20 to 0.40 0.80

♦ Feeler gauge
Checking ring-to-groove clearance
– Clean annular groove of piston before check.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.20
2nd compression ring 0.03 … 0.06 0.15
Oil scraper rings Cannot be measured
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Checking cylinder bores ir se
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c
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♦ Cylinder gauge - VAS 6078-

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Caution t. Cop py
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The cylinder bore may not be worked on (reboring, honing, cop Vo
by lksw
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damage the surface of the cylinder bore.

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4-cyl. direct injection engine (2.0 l, 4 V,yturbocharger,
Volk chain drive, generation
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tho eo
au ra
– Using a cylinder gauge - , take measurements at sVAS 6078-
s c
ce
le
3 positions diagonally in the lateral direction -A- and in the
un
pt
longitudinal direction -B-.
an
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♦ Difference between actual and nominal diameter max.
pe
ility
0.08 mm.
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Cylinder bore ∅
spec
Basic dimension mm 82.51
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
nform
mercia
a
5.5 Checking radial clearance of conrods
com
tion in
r
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thi
s
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♦ Plastigage
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Procedure
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Cop py
– Remove conrod bearing cap. ht. rig
rig ht
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– Clean bearing cap and bearing journal.
by lksw
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Prote AG.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts
⇒ Item 1 (page 76) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.02 to 0.06 mm
• Wear limit: 0.09 mm.
– Renew conrod bolts.

- Edition 12.2017
15 – Cylinder head, valve gear

1 Cover for timing chain
⇒ “1.1 Assembly overview - cover for timing chain”, page 82
⇒ “1.2 Removing and installing upper timing chain cover”,
page 84
⇒ “1.3 Removing and installing timing chain cover (bottom)”, page
86
1.1 Assembly overview - cover for timing chain
1 - Bolt
❑ 4 Nm 45°
2 - Exhaust camshaft control
valve 1 - N318-
⇒ page 165
3 - Oil seals
❑ To remove, cover must
be removed.
4 - Timing chain cover (top)
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5 - Seal ut
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6 - Cap
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7 - Bolt
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❑ 9 Nm
spec
t to the co
8 - Seal
❑ Renew if damaged
9 - O-ring rrectne
ss
❑ Moisten with engine oil.

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10 - Not installed
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11 - Engine
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12 - Dowel pins
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13 - Lower timing chain cover

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14 - Seal Prote
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agen
❑ For vibration damper.

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

- Edition 12.2017
15 - Plug
16 - Bolt
❑ Cover – tightening sequence for version with 8 bolts ⇒ page 83
❑ Cover – tightening sequence for version with 15 bolts ⇒ page 84
17 - O-ring
❑ Lubricate before assembling.
18 - Dipstick guide tube
19 - Bolt
❑ 9 Nm
20 - Inlet camshaft control valve 1 - N205-
Timing chain cover (top), tightening sequence

– Tighten bolts -1 to 6- in the sequence shown. Use torque
wrench - V.A.G 1783- and open-end spanner insert AF 10 -
V.A.G 1783/1- for bolts -3- and -5-.
AG. Volkswagen AG d
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Lower timing chain cover – tightening sequence, 8 bolts
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spec
Do not tighten bolts -1- and -4- with turning further angle until after
t to the co
the vibration damper has been installed. The bolts must be un‐
screwed again for installing the vibration damper. Note the differ‐
ent torques for steel bolts and aluminium bolts!
rrectne
Stage Steel bolts Specified torque/turning further angle
s
for steel bolts
s o
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1. -1 … 8- 8 Nm
form
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2. -1 … 8- 45°
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Stage Aluminium bolts Specified torque/turning further angle

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for aluminium bolts

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Prote AG.
1. Cover for timing chain 83

- Edition 12.2017
Lower timing chain cover - tightening sequence, 15 bolts
Note
Do not tighten bolts -3- and -6- with turning further angle until after
the vibration damper has been installed. AGThe
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2. -1 … 15- 45°
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Stage Aluminium bolts Specified torque/turning further angle
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for aluminium bolts
spec
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1. -1 … 15- 4 Nm
t to the co
2. -1 … 15- 45°
rrectness of i
1.2 Removing and installing upper timing
l purpos
chain cover
nf
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Prote AG.
♦ Torque wrench - V.A.G 1783-
♦ Open-end spanner insert (10 mm) - V.A.G 1783/1-

♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

- Edition 12.2017
Removing
• Engine cold.
. Volkswagen AG
a gen AG does
– Briefly open filler cap -arrow- for coolant expansion
Vol
ksw tank in or‐ not
gu
der to reduce residual pressure in coolinged by system. ara
nte
is
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– Remove engine cover panel ⇒ page
au 38 .
th ra
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spec
– Release hose clip -1-, disconnect coolant hose and push to‐
wards right.
t to the co
– Disconnect hose -2- for activated charcoal filter (press release
tab on hose) and move hose clear.
rrectne
– Remove inlet camshaft control valve 1 - N205- / exhaust cam‐
shaft control valve 1 - N318- ⇒ page 165 .
ss o
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mer
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– Unclip retainer for wiring harness -2-.

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– Remove bolt -1- for dipstick guide tube. t. Cop py
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– Unclip guide tube from timing chain cover (top) in direction of pyri by
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– Unscrew bolts -1 … 6-.

– Remove upper timing chain cover.
– If necessary, remove bolts -3 and 5-.
Installing
Note
Renew sealing rings.
– Remove sealant residue on bearing saddle.

– Remove any oil and grease from sealing surfaces.

- Edition 12.2017
Note
Observe use-by-date of sealant.
– Cut off nozzle on tube at front marking (∅ of nozzle approx. AG. Volkswagen AG d
agen
1.5 mm). Volksw
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Risk of lubrication system becoming clogged due to excess

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♦ Do not apply sealant bead thicker than specified.
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– Apply beads of sealant -arrows- onto clean oil seals as shown
spec
in illustration.
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• Thickness of sealant beads: 2 mm.
rrectness of i
Note
l purpos
The upper timing chain cover must be installed within 5 minutes

after sealant has been applied.
nform
mercia
a
– Install upper timing chain cover. Observe tightening sequence
com
tion in
⇒ page 83 .
r
te o
thi
– Install camshaft control valve 1 - N205- and exhaust camshaft
s
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control valve 1 - N318- ⇒ page 165 .

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– Fit engine cover panel ⇒ page 38 .

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Specified torques
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♦ ⇒ “1.1 Assembly overview - cover for timing chain”, page 82
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Prote AG.
1.3 Removing and installing timing chain

cover (bottom)
Note
Due to the adhesive strength of the sealant, the cover is bent

when being removed. For this reason, the cover always needs be
renewed.

- Edition 12.2017
♦ Silicone sealant ⇒ Electronic parts catalogue

agen
AG. V(ETKA)
olkswagen AG
do
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Removing d byV ua
ran
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– Remove front right wheeluthhousing liner ⇒ General body re‐
o
or
ac
a
pairs, exterior; Rep. gr.ss 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
ce
le
un
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an
d
itte
– Remove engine support ⇒ page 49 .
y li
rm
ab
pe
– Remove vibration damper ⇒ page 44 .
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– Remove valve for oil pressure control - N428- ⇒ page 186 .
h re
hole
spec
– Remove tensioner for poly V-belt ⇒ page 42 .
es, in part or in w
t to the co
– Unclip retainer for wiring harness -2-.
– Remove bolt -1- for dipstick guide tube.
rrectness of i
– Unclip guide tube from timing chain cover (top) in direction of
-arrow-.
l purpos
– Pull dipstick guide tube out of the timing chain cover.

nform
mercia
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tion in
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Cover with 8 bolts
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– Lever lower timing chain cover off. Prote
cted AG.
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- Edition 12.2017 auth or
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Cover with 15 bolts
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– Unscrew bolts -1 … 15-.
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– Lever lower timing chain cover off.
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Installing
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Note
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♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA) .
nform
ercia
♦ The cover must be installed within 5 minutes after applying the

silicone sealant.
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♦ Renew seal and O-ring.
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♦ Danger of soiling lubrication system. Cover open parts of en‐
fo
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– Remove sealant residues from cylinder block with a flat scra‐ py by
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– Remove any oil and grease from sealing surfaces.
– Check that both dowel pins for centring the cover -arrows- are
fitted.

3 mm).

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4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, tchain
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c
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nl
pt
Seal cover with 15 bolts
du
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itte
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erm
– Apply silicone sealant to clean sealing surface -arrow 1- and
ab
ility
to edges -arrows 2- of new cover as shown in illustration.
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spec
es, in part or in w
t to the co
Note
rrectness of i
silicone sealant.
l purpos
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
nform
ercia
♦ After fitting cover, let sealant dry for approx. 30 minutes. Only
m
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then fill with engine oil.
ion
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– Install cover immediately and tighten bolts, tightening se‐

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– Apply silicone sealant to clean sealing surface -arrow 1- and p by
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to edges -arrows 2- of new cover as shown in illustration.
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♦ Thickness of sealant bead: 2 to 3 mm.
Note

silicone sealant.
♦ After fitting cover, let sealant dry for approx. 30 minutes. Only
then fill with engine oil.
– Install cover immediately and tighten bolts, tightening se‐

quence ⇒ page 83 .
Continued for all:
– Install valve for oil pressure control - N428- ⇒ page 186 .
– Install tensioner for poly V-belt ⇒ page 42 .
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Replenish engine oil, and check oil level ⇒ Maintenance ;
Booklet ; Engine oil: Draining; Renewing oil filter and replen‐
ishing engine oil .
Specified torques
♦ ⇒ Fig. ““Engine support - specified torque and installation se‐
quence”“ , page 50

Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014ge➤ n A,GGolf
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4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain
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- Edition 12.2017 ir se
d ara
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2 Chain drive
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⇒ “2.1 Assembly overview - camshaft timing chains”, page 90
rm
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⇒ “2.2 Assembly overview - drive chain for balance shaft”,
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page 92
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⇒ “2.3 Removing and installing camshaft timing chain”,
spec
es, in part or in w
page 94
t to the co
⇒ “2.4 Removing and installing drive chain for balance shaft”,
page 107
rrectness of i
⇒ “2.5 Checking chain elongation”, page 109
l purpos
⇒ “2.6 Checking valve timing”, page 109
2.1 Assembly overview - camshaft timing
nform
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chains
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Guided Functions ⇒ Vehicle diagnostic tester.
t. rig
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1 - Bolt
❑ 4 Nm +90°
2 - Chain tensioner
❑ Is spring-loaded
❑ Secure with locking tool
- T40267- before remov‐
ing.
3 - Tensioning rail for timing
chain
4 - Guide pin
❑ 20 Nm
5 - Bolt
❑ 4 Nm +180°
6 - Regulating valves
❑ Left-hand thread
❑ Depending on version,
remove using removal
tool - T10352/2- or -
T10352/4- .
❑ 35 Nm
7 - Bearing saddle
8 - Guide rail for camshaft tim‐
ing chain
9 - Camshaft case
10 - Camshaft timing chain
❑ Before removing, mark
running direction with

- Edition 12.2017
paint
11 - Guide rail for camshaft timing chain
12 - Guide pin
❑ 20 Nm
13 - Triple chain sprocket
❑ Crankshaft
❑ Fitting position ⇒ page 91
Triple chain sprocket - installation position

• The two sections -arrows- must be aligned.
AG. Volkswagen AG d
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Prote AG.
2. Chain drive 91
- Edition 12.2017
2.2 Assembly overview - drive chain for balance shaft
1 - Guide pin
❑ 20 Nm
2 - Tensioning rail
❑ For timing chain
3 - Balancer shaft
❑ Exhaust side
newed if removed. n AG. Volkswagen AG do
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❑ Lubricate bearing withby Volk ot g
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❑ Renewing ⇒ pageau
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4 - Guide pin
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❑ 20 Nm
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5 - Slide rail
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❑ For timing chain
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6 - Chain tensioner
spec
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❑ 85 Nm
t to the co
❑ Insert with locking fluid;
locking fluid ⇒ Electron‐
ic parts catalogue (ET‐
rrectness of i
KA)
l purpos
7 - Seal
8 - Cylinder block
nf
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9 - O-ring
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10 - Bearing mounting
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❑ Lubricate with engine oil

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⇒ page 93 Cop py
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11 - Intermediate gear p by
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❑ If bolt ⇒ Item 13 (page 92) has been loosened, renew idler gear.
agen
Prote AG.
12 - Thrust washer
13 - Bolt
❑ If bolt has been loosened, idler gear ⇒ Item 11 (page 92) will need to be renewed.
14 - Slide rail
❑ For balancer shaft timing chain
15 - Guide pin
❑ 20 Nm
16 - Balancer shaft
❑ Inlet side
❑ Must always be renewed if removed.
❑ Lubricate bearing with engine oil

- Edition 12.2017
17 - Triple chain sprocket

18 - Drive chain for balance shafts
❑ Removing ⇒ page 107
Bearing mounting - installation position agen

AG. Volkswagen AG d
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• Renew O-ring -1- and lubricate with oil. ed by
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• Dowel pin -arrow- for bearing mounting mustaut engage in bore
ho eo
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in cylinder block. ss c
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• Lubricate bearing mounting.
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Tightening sequence - idler gear
rrectness of i
Caution
l purpos
The idler gear must always be renewed. Otherwise no tooth

backlash is set, causing damage to the engine.
nform
ercia
The new idler gear is coated with a solid film lubricant that
m
a
com
ti
wears off after a short period as a result of which the tooth
on in
backlash is automatically set.
r
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– Tighten as follows using new bolt:
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1. Pre-tighten to 10 Nm using torque wrench. C py
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2. Turn idler gear.
op Vo
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There must be no play in idler gear. If it does, release and then
AG.
retighten.
3. Tighten to 25 Nm using torque wrench.
4. Use fixed wrench to turn 90° further.
2. Chain drive 93
- Edition 12.2017
2.3 Removing and installing camshaft timing chain

equipment required
AG. Volkswagen AG d
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s
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t.
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Cop py
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Prote AG.
♦ Removal tool - T10352-

♦ Pin - T40011-
♦ Assembly lever - T40243-
♦ Locking tool - T40267-
♦ Camshaft clamp - T40271-

AG. Volkswagen AG d
agen oes
olksw not
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Golf 2013 ed ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf
b ara Variant 2014 ➤ , Golf V ...
nte
ris
4-cyl. direct injection engine (2.0
ut
h l, 4 V, turbocharger, chain drive, generatione oIII) Volkswagen R GmbH
o
ra
a
ss c - Edition 12.2017
ce
e
nl
pt
du
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ility
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Components of assembly tool - T10531- :

♦ Support - T10531/1-
♦ Clamping pin - T10531/2-
♦ Turning over tool - T10531/3-
♦ Collar nut - T10531/4-
Removing
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
2. Chain drive 95
- Edition 12.2017
With markings on cylinder head

– Turn vibration damper to TDC position using counter-hold tool
- T10355- .
• The markings -1- on the camshaft sprockets must align with
markings -2 and 3-.
• The notch on the vibration damper must align with the marking
on the lower timing chain cover -arrow-.
AG. Volkswagen AG d
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• The markings -1- on the camshaft sprockets must face up‐
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on the lower timing chain cover -arrow-. spec

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– Turn assembly tool - T10352/2- or -T10352/4- in -1- in direction

i
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of -arrow- to remove left and right timing valves.

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Cop py
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♦ The timing valves have left-hand threads.
Prote AG.
♦ Depending on the version, different timing valves may be in‐

stalled. Use the appropriate assembly tool -1-.

- Edition 12.2017
– Unscrew bolts -arrows- and remove bearing saddle.
AG. Volkswagen AG d
agen oes
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du
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– Screw in lever - T40243- -arrows-.
erm
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– Press together retaining ring -1- of chain tensioner and hold it
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in that position.
h re
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spec
– Slowly push lever - T40243- in -direction of arrow-, and hold it
es, in part or in w
in that position.
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– Secure chain tensioner with locking pin - T40267- .
rig
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– Remove lever - T40243- .
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2. Chain drive 97
Golf 2013 ➤ , Golf 2015en➤ AG,. Golf 2017
Volkswagen A➤G d,oGolf Variant 2014 ➤ , Golf V ...
ag
4-cyl. direct injection
Volkswengine (2.0 l, 4 V, turbocharger,
es n
ot g chain drive, generation III) Volkswagen R GmbH
by ua
- Edition 12.2017
rised ran
t
ee
tho or
au a
– Bolt camshaft clamp
- T40271/2- to cylinder head and
ss insert it c
between teeth of sprocket in direction of -arrow 2-. If neces‐
ce
le
un
pt
sary, turn inlet camshaft in direction of -arrow 1- using assem‐
an
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bly tool and adapter - T40266- .
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es, in part or in w
t to the co
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– Bolt camshaft clamp - T40271/1- to cylinder head.
nform
ercia
A second mechanic is required for the following work step.

m
– Using assembly tool - T40266- , locate exhaust camshaft in
a
com
tio
direction of arrow -A-. Remove bolt -1- and guide tensioning
n in
r
rail -2- downwards. Turn exhaust camshaft clockwise -A- until

te o
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camshaft clamp - T40271/1- can be inserted in teeth of chain
s
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sprocket -C-.
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Prote AG.
– Remove guide rail -1-. To do this, use a screwdriver to release

catch -arrow-, and press off guide rail forwards.
– Unscrew bolts -arrows-, and remove chain tensioner -1-.

- Edition 12.2017
– Press tensioning bar of oil pump chain tensioner in direction

of -arrow- and lock it with locking pin - T40011- .
– Remove chain tensioner -2-.
– Unscrew bolts -1-.

– Remove guide rail -2-.
– Remove camshaft timing chain from camshaft sprockets and

fit it onto camshaft journals -arrows-.
AG. Volkswagen AG d
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spec
– Remove chain tensioner -1- for balance shaft timing chain.

t to the co
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cial p
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op Vo
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Prote
cted AG.
agen 2. Chain drive
- Edition 12.2017

– Remove tensioning rail -2- and guide rails -3 and 4-.
– Loosen tensioning bolt -A-.

– Unscrew clamping pin -B-.
– Remove triple chain sprocket. To do this, remove timing chain
for oil pump drive.
– Remove camshaft timing chain and drive chain for balance
shaft.
Installing
– Check if crankshaft is positioned at TDC. The flat section on
crankshaft -arrow- must be horizontal. AG. Volkswagen AG d
agen oes
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– Using a permanent felt tip marker, make a marking bonyV
ocylinder
l not
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block -1-, as shown in illustration. ris
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– Mark tooth -1- of triple chain sprocket which is aligned with

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marking -2- using a permanent felt tip marker.

hole
spec
es, in part or in w
t to the co
rrectness of i
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om
ion
c
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ate
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for
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
– Turn idler gear and balance shaft so that markings -arrow- are
aligned as shown in illustration. Do not loosen bolt -1-. The
markings on idler gear and balance shaft are difficult to see.
– Fit drive chain for balance shafts. Position chain links with col‐
oured markings -arrows- at markings on chain sprockets.
AG. Volkswagen AG d
agen oes
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– Install guide rail -1-, and tighten bolts -arrows-.
ility
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cial p
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mer
atio
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– Fit camshaft timing chain onto camshaft journals with coloured

o
n
c
markings -arrows- properly aligned.

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Cop py
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co Vo
by lksw
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Prote AG.
2. Chain drive 101

- Edition 12.2017
– Fit timing chain for oil pump drive onto triple chain sprocket.
– Swing triple sprocket towards engine (-direction of arrow-),
and fit it onto crankshaft. The markings -arrows- must align.
I - Screw clamping pin - T10531/2- into crankshaft, and tighten it

by hand.
G. Volkswagen AG d
II - Fit turning over tool - T10531/3- . Screw on flange nut - lksw
agen
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not
T10531/4- by hand. Slightly move turning over tool back and forthby Vo gu
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with a 32 mm open-end spanner. While doing so, retighten flange or
ise
d
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nut until the chain sprocket is securely seated on the crankshaft
au
th eo
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splines. Now, tighten tensioning bolt -A-. ss c
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– Position link of drive chain for balance shafts with coloured

marking -arrow- at marking of triple sprocket. Install tensioning
nform
ercia
rail -1- and guide rail -2-. Tighten bolts -3-.

m
at
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ion
c
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Prote AG.

- Edition 12.2017
– Install chain tensioner -1-.
– Make sure that adjustment has been carried out correctly:

chain links with coloured markings -arrows- must be posi‐
tioned at markings on chain sprockets.
– Fit camshaft timing chain on inlet camshaft, exhaust camshaft

and crankshaft. Position chain links with coloured markings
-arrows- at the markings on chain sprockets.
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Prote AG.
2. Chain drive 103

- Edition 12.2017 wage
e ks s no
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by ara
– Install guide rail -2-, and
ris tighten
ed bolts -1-. nte
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– Install upper guide rail -1-.
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I - Turn exhaust camshaft in -direction of arrow A- using assembly
tool - T40266- , and remove camshaft clamp - T40271/1- from
between teeth of chain sprocket -B-.
II - Release tension from camshaft in -direction of arrow C- until
timing chain rests against guide rail -1-. Hold camshaft in this po‐
sition, install tensioning rail -2-, and tighten bolt -3-.

- Edition 12.2017
– Install chain tensioner -1-, and tighten bolts -arrows-.
– Install chain tensioner -2-. The retaining clip -arrow- must be

seated in recess in top section of sump. Tighten bolt -1-, and
remove locking pin - T40011- .
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– Using
utho assembly tool - T40266- , turn inlet camshaft e o in
ra
-direction
ss a of arrow 1- until camshaft clamp - T40271/2-
can be c
removed from between teeth of chain sprocket -2-. Relieve
ce
le
un
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tension from camshaft.

an
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– Remove camshaft clamp - T40271/1- and -T40271/2- .

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2. Chain drive 105

- Edition 12.2017
– Screw in and tighten bolts -arrows-.
– Moisten holes -arrows-awith engine

gen AG
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Note uthor tee
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– Fit bearing saddle. Do not cant bearing saddle, while doing so.
Screw in bolts -1 to 6- by hand.
rrectness of i
– If a spring pin is installed, it is pulled into the cylinder head

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together with bolt -1-.

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– Remove locking tool - T40267- .
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Prote AG.

- Edition 12.2017
– Tighten bolts -arrows- for bearing saddle.

– Install timing valves ⇒ Item 6 (page 90) .
– Turn engine two revolutions in direction of engine rotation.
Note
Due to the ratio, the coloured chain links do not align with the
markings any more after the engine has been turned.
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– Remove turning over tool, and sinstall
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⇒ page 86 . s
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, is n
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the vibration damper has been installed. The bolts must be un‐
hole
spec
screwed again for installing the vibration damper.
es, in part or in w
t to the co
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ercia
– After working on the chain drive, adapt learnt values in engine

control unit ⇒ Vehicle diagnostic tester.
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Specified torques
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♦ ⇒ “2.1 Assembly overview - camshaft timing chains”,

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page 90
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General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Prote
cted AG.
agen
2.4 Removing and installing drive chain for

balance shaft
Removing
– Remove camshaft timing chain ⇒ page 94 .
– Remove bolts -arrows- and take off tensioner -1- for camshaft
timing chain.
2. Chain drive 107

- Edition 12.2017
– Remove guide rail -3-.

– Remove drive chain for balance shafts.
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Installing auth or
ac
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– Turn idler gear and balance shaft so that markings -arrow- are
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aligned as shown in illustration. Do not loosen bolt -1-.
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Note
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The links of the drive chain for balance shafts with coloured mark‐
m
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ings must be positioned at the markings on the sprockets.
om
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– Fit drive chain for balance shafts. The chain links with coloured
t
sd
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markings -arrows- must be positioned at the markings on the

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sprockets.
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Prote AG.
– Fit guide rail for timing chain and tighten bolts -3-.

- Edition 12.2017
– Install chain tensioner -1- for camshaft timing chain.

Specified torques
page 90
♦ ⇒ “2.2 Assembly overview - drive chain for balance shaft”,
page 92
2.5 Checking chain elongation
Note
If complaints (e.g. noise) indicate a stretched camshaft timing

chain, check timing chain as described below.
– Remove sealing plug -arrow-. The sealing cap must be re‐

newed.
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– Turn vibration damper in direction of engine d rotation until pis‐
b ua
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ton of chain tensioner is fully extended thino -direction of arrow-. tee
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– Count piston notches that are visible.ss
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Visible notches are those located to the right from the chain ten‐
, is n
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sioner housing -arrow-.

hole
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es, in part or in w
♦ If 6 or less notches are visible, the camshaft timing chain must

t to the co
not be renewed.
♦ If 7 or more notches are visible, renew camshaft timing chain
rrectness of i
⇒ page 94 .
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2.6 Checking valve timing

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Prote AG.
2. Chain drive 109

- Edition 12.2017
♦ Dial gauge set, 4-part - VAS 6341-
♦ Dial gauge adapter - T10170 A-

sulation . . Volkswag AG en AG
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– Remove washer fluidyreservoir
Vol
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92 ; Windscreen washer
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– Using 24 mms socket, turn crankshaft via vibration damper in
ce
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normal direction of rotation until markings -arrows- are almost

nl
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– Remove spark plug from cylinder 1 ⇒ page 346 .

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Prote AG.

- Edition 12.2017
– Screw dial gauge adapter - T10170/A- into spark plug hole to

stop.
– Insert dial gauge - VAS 6341- with extension - T10170A/1- as
far as it will go and secure in place with self-locking nut
-arrow-.
– Slowly turn crankshaft in engine DOR to maximum needle de‐
flection. Once maximum needle deflection is reached (reverse
point of needle), piston is at »TDC«.
AG. Volkswagen AG d
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♦ Use a ratchet spanner with a 24 mm socket
ss or the counterhold c
tool - T10355- to turn the vibration damper.
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♦ If the crankshaft has been turned beyond “TDC”, turn it another
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two revolutions in direction of engine rotation. Do not turn en‐
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timing chain cover (bottom) -arrow-.
rrectness of i
markings -2 and 3- on cylinder head.
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Without markings on cylinder head

• Notch on vibration damper must align with marking on lower
timing chain cover -arrow-.
• The markings -1- on the camshaft sprockets must face up‐
wards.
2. Chain drive 111

- Edition 12.2017
– Measure distance from edge -1- to marking -2- on exhaust

camshaft sprocket.
• Specification: 74 … 77 mm.
– If the specified value is achieved, measure the distance be‐

tween the marking on the exhaust camshaft sprocket -3- and
the marking on the inlet camshaft sprocket -4-.
• Specification: 124 … 127 mm. AG. Volkswagen AG d
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Note horise nte
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An offset of one tooth results in a deviation of approx. 6 mm from s ce
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the specified value. If an offset is found, the timing chain must be

pt
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re-fitted.
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- Edition 12.2017
3 Cylinder head
⇒ “3.1 Assembly overview - cylinder head”, page 113
⇒ “3.2 Removing and installing cylinder head”, page 115
⇒ “3.3 Removing and installing vacuum pump”, page 123
⇒ “3.4 Checking compression”, page 124
3.1 Assembly overview - cylinder head
Note
♦ Renew cylinder head

agebolts.
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♦ Always renew
ed
by self-locking nuts, bolts which have
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ened with ho
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kets.s aut or
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♦ The plastic protectors fitted to protect the open valves must
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only be removed immediately before fitting the cylinder head.
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♦ After fitting a new cylinder head or cylinder head gasket,
ab
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change the engine oil and coolant.
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1 - Dowel pin spec

es, in part or in w
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2 - Cylinder head gasket
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❑ Observe installation po‐

sition: Part number to
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cylinder head
3 - Cylinder head
nf
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❑ Check for distortion

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⇒ page 115 .
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tightening ⇒ page 115 .
5 - Heat shield
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
8 - Heat shield
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Union
❑ For coolant hose
3. Cylinder head 113

- Edition 12.2017
12 - O-ring
❑ Moisten with coolant
13 - Cylinder head bolts wage
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❑ Renew after removal d by V ua
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❑ Note procedure when tho loosening ⇒ page 114 . tee
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15 - Union
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❑ For coolant hose
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16 - Bolt
❑ 9 Nm
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17 - Support bearing
❑ For engine cover panel
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18 - Engine lifting eye
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19 - Bolt
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❑ 8 Nm +90°
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20 - Partition
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23 - Bolt
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Prote AG.

❑ 8 Nm +90°
24 - Dowel pin
Loosening cylinder head bolts

– Slacken cylinder head bolts in the sequence -1 to 10-.

- Edition 12.2017
Tightening sequence for cylinder head

– Tighten cylinder head bolts in the sequence -1 … 10- as fol‐
lows:
1. Tighten initially to 40 Nm using torque wrench
4. Pre-tighten bolts -arrows- to 4 Nm.
5. Turn bolts -arrows- 90° further using a rigid wrench.
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
♦ Max. permissible distortion: 0.05 mm
3.2 Removing and installing cylinder head

olkswagen AG
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Special tools and workshop equipment requiredolkswag does
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♦ Engine bung set - VAS 6122- rise nte
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♦ Special wrench, long reach - T10070-

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- Edition 12.2017
Removing
Note
♦ Fit all cable ties in the original position

wage
nwhen
AG. Volinstalling.
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♦ Always make sure to seal the
ed open channels of the intake and
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exhaust sections with suitable
horis plugs. For example, those from nte
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engine bung set - VAS
s aut 6122- . ra
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– Remove camshafts ⇒ page 131 .
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⇒ page 339 .
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– Remove Lambda probe 1 before catalytic converter - GX10-
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⇒ page 322 .
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– Seal open lines and connections with clean plugs from engine Prote AG.

- Edition 12.2017

– Unplug electrical connector -1- at charge pressure sender -
G31- and detach air pipe (right-side).
– Release hose clips -arrows- and detach coolant hoses.

– Swivel coolant line -1- to side.
AG. Volkswagen AG d
– Disconnect connectors -1, 2 and 3-. agen oes
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rrectness of i
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Prote AG.

- Edition 12.2017
– Unscrew bolt -1- and nut -3- and remove bracket -2- for intake
manifold.
– Separate connectors:
1- For throttle valve module - GX3-
2- For intake manifold sender - GX9- .
3- For fuel pressure sender - G247- .
– Remove connector -4- from retainer.
– Move electrical wiring harness clear and press to one side.
– Free electrical wiring harnesses -1- and -2- from fittings and ks
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– Loosen screw-type clip -3-. edb ara
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– Loosen hose clip -arrow-, and remove charge air hose -1-
downwards, together with air pipe.
rrectness of i
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tion in
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te o
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Prote AG.

- Edition 12.2017
– Remove connector -3- for knock sensor 1 - G61- from retainer

and disconnect it.
– Disconnect connectors -2 and 4-.
– Separate connectors and lay wiring harnesses to one side:

1- For intake manifold flap valve - N316- .
2- For coolant shut-off valve - N82- .
3- For coolant temperature sender - G62-
4- For stage 3 oil pressure switch - F447-
– Unscrew bolts -arrows- and nut -1-. AG. Volkswagen AG d

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– Remove heat shield -2-. ised b ara
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– Remove bolt -1- and loosen bolt -3-.
rrectne
– Remove bracket -2- for turbocharger.
ss o
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Prote AG.

- Edition 12.2017
– Unscrew nuts -arrows-.

– Detach turbocharger from cylinder head and tie up to rear.
AG. Volkswagen AG d
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Prote AG.

- Edition 12.2017

– Use special wrench (Polydrive) - T10070- to remove cylinder
head bolts in the sequence -1 … 10-.
Note
♦ Make sure all hoses/pipes and wiring are removed.

olkswagen AG
en AG. V
♦ Ensure tensioning rail and guide rail are not damaged owhen
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– Remove cylinder head. ss
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– Place cylinder head onto soft surface (foam plastic).
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Caution
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Risk of damage to the sealing surfaces
♦ Carefully remove sealant residue from cylinder head and
rrectness of i
cylinder block.
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♦ Ensure that no long scores or scratches are made on the

surfaces.
nform
ercia
Risk of damage to the cylinder block

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♦ No oil or coolant must be allowed to remain in the blind
at
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holes for the cylinder head bolts in the cylinder block.
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Risk of leakage on cylinder head gasket

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♦ Carefully remove remains of emery and abrasives.
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damage to the silicone coating or the indented area of the Prote AG.
gasket.
Risk of damage to the open valves
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Risk of damage to valves and piston crowns after working on
the valve gear
♦ Carefully turn the engine at least 2 full revolutions to en‐
sure that none of the valves makes contact when the
starter is operated.

- Edition 12.2017
Note

♦ Renew gaskets, oil seals and self-locking nuts.
♦ Note the different sealants for sealing surfaces and cylinder
head bolts. AG. Volkswagen AG d
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♦ To ensure that the charge air hoses can be properly secured
spec
at their connections, spray rust remover onto the worm thread
of used hose clips before installing.
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♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and coolant.
rrectnes
– Position cylinder head gasket.
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♦ Note centring pins in cylinder block -arrows-.
nform
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♦ Check installation position of cylinder head gasket. Charac‐ atio

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– If crankshaft has since been turned, position cylinder number Prote AG.
1 piston to TDC and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Bolt tightening sequence for cylinder head
⇒ Fig. ““Tightening sequence for cylinder head”“ , page 115
Note
After repair work it is not necessary to retighten the cylinder head

bolts.

- Edition 12.2017

- T10355- .
– Install camshafts ⇒ page 131 .
– Change engine oil ⇒ Maintenance ; Booklet ; Engine oil:
Draining; Renewing oil filter and replenishing engine oil .
– Fill cooling system with fresh coolant ⇒ page 198 .
– Install front exhaust pipe with catalytic converter
⇒ page 339 .
WARNING
Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.
Specified torques AG. Volkswagen AG d

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♦ ⇒ “1.1 Assembly overview - turbocharger”, page 259

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– Remove air filter housing ⇒ page 287 .
rrectness of i
– Separate vacuum hose -2-.

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– Press release tabs on vacuum hose -1-, and remove hose

from vacuum pump.
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- Edition 12.2017
– Release fastener -arrow-, detach wiring duct upwards from

bracket and press forwards.
Caution
Risk of damage to the coolant line

♦ Do not attempt to bend coolant line to a different shape.
– Unscrew bolts -1, 2 and 3-, and carefully swivel coolant line to
one side slightly.
– Remove high-pressure pump with roller tappet ⇒ page 317 .
– Unscrew bolts -arrows-, and remove vacuum pump.
Note
Dismantling of the vacuum pump is not permitted.
Installing

– Clean sealing surfaces.
– Position drive lug of vacuum pump carrier so that it engages
in slot of camshaft when vacuum pump is fitted. . Volkswag
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– Position new gasket on vacuum pump, Vol insert 2 bolts, and fit
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– When doing so, ensure thats avacuum pump is flush with flange.
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4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation
n AG. VoIII)
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Special tools and workshop tho
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♦ Spark plug socket - 3122 B-

♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1381/1-
♦ Adapter - V.A.G 1381/5A-
Test sequence
Note
♦ Engine oil temperature min. 30°C

♦ Battery voltage at least 12.7 V

– Remove ignition coils ⇒ page 347 .

- Edition 12.2017
1- For injectors -N30- to -N33-
2- For injectors 2 -N532- to -N535-
– Unscrew spark plugs using spark plug socket - 3122 B- .
AG. Volkswagen AG d
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– Check compression using compression tester - V.A.G 1763- , ss
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Compression pressures bar
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New 11.0 … 14.0
Wear limit 7.0
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– Clear any event entries which may have been stored during
the test ⇒ Vehicle diagnostic tester.

- Edition 12.2017
4 Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 127
⇒ “4.2 Removing and installing camshaft”, page 131
⇒ “4.3 Installing ball for sliding piece”, page 155
⇒ “4.4 Removing and installing valve stem seals”, page 156
⇒ “4.5 Removing and installing camshaft control valve 1 N205 /
exhaust camshaft control valve 1 N318 ”, page 165
⇒ “4.6 Removing and installing actuator for camshaft adjustment
N580 / N605 ”, page 165
4.1 Assembly overview - valve gear
Note
♦ Cylinder head and cylinder head cover must be renewed to‐

gether.
♦ After installing camshafts wait for approx. 30 minutes before
starting engine. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, carefully turn the engine at
least 2 revolutions to ensure that none of the valves makes
contact when the starter is operated.
♦ Always renew gaskets and seals.
After camshafts have been removed, chain elongation must be

adapted ⇒ Vehicle diagnostic tester.
Part I
Part II ⇒ page 129 AG. Volkswagen AG d
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4. Valve gear 127

- Edition 12.2017
1 - Outlet valve
❑ Do not rework; only
grinding-in is permissi‐
ble
❑ Valve dimensions
⇒ page 167
❑ Checking valve guides
⇒ page 166 AG. Volkswagen AG d
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❑ Oil contact surface
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8 - Retaining clip
❑ For hydraulic compen‐
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sation element.
9 - Roller rocker fingers
nform
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❑ Mark installation posi‐

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10 - Exhaust camshaft Prote
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❑ Check radial clearance with Plastigage (roller rocker fingers removed).

❑ Radial clearance: 0.024 to 0.066 mm.
❑ Runout: max. 0.04 mm
11 - Spring
❑ No replacement part
12 - Ball
❑ For sliding piece
❑ Installing ⇒ page 155
13 - Cylinder head cover
❑ With integrated camshaft bearings.
❑ Clean sealing surface; reworking is not permitted
❑ Remove sealant residue.
14 - Bolt
❑ Loosening ⇒ page 129
15 - Inlet camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed).

- Edition 12.2017
❑ Radial clearance: 0.024 to 0.066 mm.
❑ Runout: max. 0.04 mm
16 - Dowel pins
17 - Dowel pins
18 - Inlet valve
❑ Do not rework; only grinding-in is permissible
❑ Valve dimensions ⇒ page 167
❑ Checking valve guides ⇒ page 166
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nform
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2. Tighten bolts in the sequence -1 … 6- to 8 Nm using torque

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Part II
Part I ⇒ page 127
4. Valve gear 129

- Edition 12.2017
1 - Cylinder head
2 - O-ring
❑ Check for damage
❑ Not a replacement part,
provided together with
actuator for camshaft
adjustment
3 - Actuator for camshaft ad‐
justment -N580- / -N605-
⇒ page 165
4 - Bolt AG. Volkswagen AG d
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9 - Hall sender 3 - G300-

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⇒ page 346
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❑ Specified torque
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14 - Vacuum pump
15 - Bolt
❑ 8 Nm +180°
16 - Seal
17 - O-ring
18 - Hall sender - G40-
❑ Assembly overview ⇒ page 346

- Edition 12.2017
19 - Bolt
❑ Specified torque ⇒ page 346
20 - Bolt
❑ 9 Nm
21 - Bracket
❑ For activated charcoal filter system solenoid valve 1 - N80-
4.2 Removing and installing camshaft

⇒ “4.2.1 Distinguishing features of guide rail for camshaft timing
chain”, page 131
⇒ “4.2.2 Removing and installing camshaft, version A”,
page 132
⇒ “4.2.3 Removing and installing camshaft, version B”,
page 144
4.2.1 Distinguishing features of guide rail for

camshaft timing chain
Depending on the model, different guide rails may be installed.
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– Remove timing chain cover (top) ⇒ page
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⇒ page 132 .
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4. Valve gear 131

- Edition 12.2017
4.2.2 Removing and installing camshaft, version A

equipment required
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♦ Vehicle diagnostic tester
♦ Sealant - D 154 103 A1-

- Edition 12.2017
Removing
Note
♦ Sealing surfaces at bottom of cylinder head cover and top of

cylinder head must not be machined.
♦ The camshaft bearings are integrated into the cylinder head
and cylinder head cover. The camshaft timing chain must be
relieved of tension before you remove the cylinder head cover.
♦ Fit the cable ties in theagoriginal
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– Unplug electrical connectors -arrows- at actuators for cam‐
shaft adjustment.
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– Unscrew bolt -5-, free earth cable from fittings and lay it to one
side. ss
– Move electrical wiring harness clear at clip -4- and swivel it
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– Unscrew bolts -1, 2 and 3-, and carefully swivel coolant line
Prote AG.
towards rear slightly.
4. Valve gear 133

- Edition 12.2017
– Separate connector -1- from activated charcoal filter solenoid

valve 1 - N80- .
– Press release tabs on crankcase breather hose -2- and detach
hose.
– Unscrew bolts -arrows- and remove crankcase breather.
– Remove high-pressure pump ⇒ page 317 .
– Remove vacuum pump ⇒ page 123 .
insulation .
– Remove front part of right wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
AG. Volkswagen AG d
– Remove timing chain cover (top) ⇒ page 84 . agen oes
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♦ The timing valves have left-hand threads.
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♦ Depending on the version, different timing valves may be in‐
– Turn assembly tool - T10352/2- in -direction of arrow- to re‐

move left and right timing valves.

AG. Volkswagen AG d
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in that position.
in that position.
– Secure chain tensioner with locking pin - T40267- .

– Remove lever - T40243- .
4. Valve gear 135

- Edition 12.2017
– Screw camshaft clamp - T40271/2- onto cylinder head, and

insert it in teeth of chain sprocket (direction of arrow -2-). If
necessary, turn inlet camshaft using assembly tool - T40266-
-arrow 1-. agen
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– Using assembly tool - T40266- , locate exhaust camshaft in
direction of arrow -A-. Remove bolt -1- and guide tensioning
rrectness of i
rail -2- downwards. Turn camshaft clockwise -A- until cam‐
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shaft clamp - T40271/1- can be inserted in teeth of chain

sprocket -B-.
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– Press tensioning bar of oil pump chain tensioner in direction

of -arrow- and lock it with locking pin - T40011- .
– Unscrew bolt -1-, and remove chain tensioner.

- Edition 12.2017
wage es n
– Unscrew bolts -1-, and remove
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– Remove camshaft htiming
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– Fit turning over tool - T10531/3- . At “TDC position” the flat
n
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– Using assembly tool - T40266- , turn inlet camshaft in direction

of arrow -1-. Press camshaft clamp - T40271/2- -2- out of
sprocket teeth and move camshaft to rest position.
– Using assembly tool - T40266- , turn exhaust camshaft in di‐

rection of arrow -1-. Press camshaft clamp - T40271/1- -2- out
of sprocket teeth and move camshaft to rest position.
4. Valve gear 137

- Edition 12.2017
– Unscrew cylinder head cover bolts in the sequence -1 … 6-.

– Remove cylinder head cover.
– Remove camshafts, and cover open parts of engine.
Installing
Note
♦ Sealing surfaces must be free of oil and grease.

♦ Ensure that all roller rocker fingers are properly seated on
valve stem ends.
– If crankshaft has been turned in the meantime, position

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– Fit exhaust camshaft in cylinder head cover as shown in illus‐

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– Turn exhaust camshaft until markings -A and B- are aligned.
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– Apply sealant onto clean sealing surface of cylinder head cov‐

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– Slightly press on cylinder head cover with one hand, and turn
camshafts slightly while doing so, until cylinder head cover is
properly seated on cylinder head and is »free of stress«.
– Renew bolts for cylinder head cover.
– Tighten bolts in several stages, tightening sequence
⇒ page 129 .
Note
– Turn inlet camshaft in -direction of arrow A- using assembly

tool - T40266- until the markings -1 and 2- align. Insert cam‐
shaft clamp - T40271/2- between teeth of chain sprocket -B-.
4. Valve gear 139

- Edition 12.2017
– Turn exhaust camshaft in -direction of arrow A- using assem‐

bly tool - T40266- until the markings -1 and 2- align. Insert
camshaft clamp - T40271/1- between teeth of chain sprocket
-B-. Marking -2- is slightly offset towards right.
– Turn crankshaft on hexagon to “TDC position”. At “TDC posi‐

tion” the flat section -1- faces upwards.
Installing camshaft timing chain

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– Fit camshaft timing chain onto camshaft journals with coloured
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– Fit camshaft timing chain on inlet camshaft, exhaust camshaft
and crankshaft. Position chain links with coloured markings
-arrows- at the markings on chain sprockets.
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- Edition 12.2017
– Install guide rail -2-, and tighten bolts -1-.
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timing chain rests against guide rail -1-. Hold camshaft in this po‐
spec
sition, install tensioning rail -2-, and tighten bolt -3-. Then, relieve
es, in part or in w
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Prote AG.
4. Valve gear 141

- Edition 12.2017
– Using assembly tool - T40266- , turn inlet camshaft in direction

of -arrow 1- until camshaft clamp - T40271/2- can be removed
from between teeth of chain sprocket in direction of arrow
-2-. Then, relieve tension from camshaft.
– Remove camshaft clamp - T40271/1- and -T40271/2- .
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– Screw in and tighten
oris bolts -arrows-. Specified torque
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Spring pin -1- is not fitted on all bearing saddles.

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– Fit bearing saddle. Do not cant bearing saddle, while doing so. Prote AG.
Screw in bolts -arrows- and tighten by hand.

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4-cyl. direct injection engine
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ran
s
thori tee
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au ra
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– Install chain tensioner -2-. The retaining clip -arrow- must be

seated in recess in top section of sump. Tighten bolt -1-, and
remove locking pin - T40011- .

– Install timing valves ⇒ Item 6 (page 90) .
– Turn engine two revolutions in direction of engine rotation.
Note
Due to the ratio, the coloured chain links do not align with the
markings any more after the engine has been turned.
4. Valve gear 143

- Edition 12.2017
– Unscrew flange nut - T10531/4- , and remove turning over tool

- T10531/3- .
Note wage
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Do not tighten bolts -1 and 4- with turning furtherrisangle
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– Install vacuum pump ⇒ page 123 .
– Installing high-pressure pump ⇒ page 317 .
rrectne
– After working on the chain drive, adapt learnt values in engine
control unit ⇒ Vehicle diagnostic tester.
ss
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page 90
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♦ ⇒ “2.2 Assembly overview - drive chain for balance shaft”, n

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4.2.3 Removing and installing camshaft, version B

- Edition 12.2017

equipment required
AG. Volkswagen AG d
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Removing
Note
♦ Fit all cable ties in the original position when installing.

♦ Sealing surfaces at bottom of cylinder head cover and top of
cylinder head must not be machined.
♦ The camshaft bearings are integrated into the cylinder head
and cylinder head cover. Camshaft timing chain must be re‐
lieved of tension before you remove cylinder head cover.
4. Valve gear 145

- Edition 12.2017

insulation .
– Remove upper coolant pipe ⇒ page 246 .
1- For turbocharger air recirculation valve - N249- .
2- For Hall sender 3 - G300-
3- For fuel pressure regulating valve - N276- .
– Unplug electrical connectors -arrows- at actuators for cam‐
shaft adjustment.
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– Unscrew bolt -5-, freeVearth
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Caution
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Risk of damage to the coolant line

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♦ Do not attempt to bend coolant line to a different shape.

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– Unscrew bolts -1, 2 and 3-, and carefully swivel coolant line
l purpos
towards rear slightly.

nf
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– Separate connector -1- from activated charcoal filter solenoid

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valve 1 - N80- .
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– Unscrew bolts -arrows- and remove crankcase breather.

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– Remove actuators for camshaft adjustment ⇒ page 165 . t. Cop py
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- Edition 12.2017

Caution
The regulating valves have left-hand threads.

Depending on the version, different timing valves may be in‐

- T10355- .
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147
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Prote 4. Valve gear
AG.
- Edition 12.2017
Without markings on cylinder head

- T10355- .
• The markings -1- on the camshafts must face upwards.
– Mark positions of sprocket markings -1- on camshaft timing

chain and cylinder head -arrows- using a permanent felt tip
marker.
– Also mark alignment of camshaft timing chain -2- relative to
guide rail of camshaft timing chain using a permanent felt tip
marker.
AG. Volkswagen AG d
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AG. Volkswagen AG d
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4-cyl. direct injection engine th(2.0
o l, 4 V, turbocharger, chain drive, generation or a III) Volkswagen R GmbH
au
ss c - Edition 12.2017
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nl
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A second mechanic is required for the following work steps.
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– Secure chain tensioner with locking pin - T40267- . t. Cop py
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– Remove lever - T40243- . pyri by
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– Bolt camshaft clamp - T40271/2- to cylinder head and insert it

between teeth of sprocket in direction of -arrow 2-. If neces‐
sary, turn inlet camshaft in direction of -arrow 1- using assem‐
bly tool and adapter - T40266- .
– Remove bolt -1- and guide tensioning rail -2- downwards.
4. Valve gear 149

- Edition 12.2017

– Turn exhaust camshaft in direction of -arrow 1- using assem‐
bly tool and adapter - T40266- , and insert camshaft clamp -
T40271/1- between teeth of sprocket in direction of
-arrow 2-.
– Mark alignment of camshaft sprockets relative to camshaft

clamp - T40271/1- and camshaft clamp - T40271/2- -arrow-.
– Use screwdriver to release fastener and press off top guide
rail towards front -1-.
– Remove camshaft timing chain from camshaft sprockets.
Caution
Risk of damage to the valves and piston crowns

♦ Do not turn the crankshaft after the camshaft timing chain
has been removed from the cylinder head.
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– Turn vibration damper horis out of “TDC” in opposite direction of ntee
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– Turn inlet camshaft in direction of -arrow 1- using assembly

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tool and adapter - T40266- , remove camshaft clamp -

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T40271/2- from between teeth of sprocket in direction of

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-arrow 2- and bring camshaft into rest position.

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– Turn outlet camshaft in direction of -arrow 1- using assembly

tool and adapter - T40266- , remove camshaft clamp -
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-arrow 2- and bring camshaft into rest position.

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– Remove high-pressure pump ⇒ page 317 .

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– Remove vacuum pump ⇒ page 123 .

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Cop py
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rig ht
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Prote AG.

- Edition 12.2017
– Unscrew cylinder head cover bolts in the sequence -1 … 6-.

– Remove cylinder head cover.
– Detach camshafts.
Caution
Risk of soiling of the lubrication system and the bearings

♦ Cover open parts of engine.
Installing
Note
♦ Sealing surfaces must be free of oil and grease.

♦ Ensure that all roller rocker fingers are properly seated on
valve stem ends.
♦ Crankshaft must not be at “TDC” position.
– Remove sealant remaining on cylinder head with flat scraper.

– If crankshaft has since been turned, position cylinder number olkswagen AG
1 piston to TDC and then turn crankshaft back slightly. swagen AG. V does
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– Remove sealant residue from groove in cylindersedhead
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– Clean sealing surfaces. They must be oil sand
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– Oil running surfaces of both camshafts.
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– If camshafts have been renewed, the markings -arrows- must
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Caution
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Risk of damage to the valves and piston crowns
♦ When installing the camshafts, the crankshaft must not be
rrectness of i
in TDC position.
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– Fit inlet camshaft -A- in cylinder head. Turn cams for cylinder
o
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or c
4 -arrows- upwards.
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Prote AG.
4. Valve gear 151

- Edition 12.2017

2 mm).
– Apply silicone sealant onto clean sealing surface of cylinder

head cover, as shown in illustration -arrows-.
Note
♦ The cylinder head cover must be installed within 5 minutes

after applying the silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐ . Volkswagen AG
wise excess sealant can enter the sump and obstruct the kswagen AG does
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Sealant ⇒ Electronic parts catalogue (ETKA) .
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– Fit exhaust camshaft in cylinder head cover as shown in illus‐
erm
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tration. Push cam pairs -A- and -B- towards each other.
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– Place cylinder head cover on cylinder head with camshaft fit‐
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– Renew bolts for cylinder head cover.
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– Tighten bolts in several stages, tightening sequence
⇒ page 129 .
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Note
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– Turn inlet camshaft in -direction of arrow 1- until marking -3-

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– Insert camshaft clamp - T40271/2- between teeth of sprocket

um
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Prote AG.

- Edition 12.2017
– Turn exhaust camshaft in -direction of arrow 1- until marking

-3- aligns with camshaft clamp - T40271/1- .
– Insert camshaft clamp - T40271/1- between teeth of sprocket
in direction of -arrow 2-.
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- T10355- .
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es, in part or in w
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ion
– Fit camshaft timing chain. When doing so, ensure that mark‐
c
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or
ings on chain links -arrows- align with markings on sprockets
his
ate
-1-.
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– Using assembly tool - T40266- , turn exhaust camshaft in di‐

rection of -arrow 1-. Remove camshaft clamp - T40271/1- from
between teeth of sprocket in direction of -arrow 2-, and relieve
4. Valve gear 153

- Edition 12.2017
– Move tensioning rail -2- upwards and screw in bolt -1-.
AG. Volkswagen AG d
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– Using assembly tool and adapter - T40266- , turn inlet cam‐
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shaft in direction of -arrow 1-: remove camshaft clamp -
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spec
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-arrow 2-, and relieve tension from camshaft.
t to the co
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Checking valve timing – with markings on cylinder head
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Prote AG.

- Edition 12.2017
Checking valve timing – without markings on cylinder head

– Check valve timing. Markings on camshaft timing chain and
cylinder head -arrows- must align with markings on sprockets.
– Markings on camshaft timing chain and on guide rail of cam‐
shaft timing chain -2- must also align.
– Notch on vibration damper must align with marking on lower
timing chain cover -3-.
Note
If the previously marked markings are no longer visible, check

valve timing ⇒ page 109 .
– Attach bearing saddle and screw in bolts -arrows- hand-tight.

– Tighten bolts -arrows- for bearing saddle ⇒ page 90 .
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– Install regulating valves ⇒ Item 6 (page
by
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– Install timing chain cover (top)th⇒
or page 84 .
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– Install vacuum pump ⇒ page
ss 123 .
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– Installing high-pressure pump ⇒ page 317 .
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– Adapt chain elongation ⇒ vehicle diagnostic tester .
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Specified torques
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4.3 Installing ball for sliding piece

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♦ Spacers - T40191-
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4. Valve gear 155

- Edition 12.2017
Installing
WARNING n AG. Volkswagen AG do

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– Insert spring -1- into camshaft.
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– Place ball -2- onto spring in camshaft.
wit
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– Using spacers - T40191/1- , press down ball and spring
hole
spec
(-arrow A-), and hold them in this position.
es, in part or in w
t to the co
– Slide sliding piece -3- in -direction of arrow B-.
rrectness of i
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⇒ “4.4.1 Removing and installing valve stem seals (cylinder head

installed)”, page 156
⇒ “4.4.2 Removing and installing valve stem seals (cylinder head
removed)”, page 161
4.4.1 Removing and installing valve stem seals (cylinder head installed)

- Edition 12.2017

equipment required
AG. Volkswagen AG d
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♦ Spark plug socket - 3122 B-

hole
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♦ Valve stem seal puller - 3364-

t to the co
♦ Valve stem seal fitting tool - 3365-

♦ Adapter - T40012-
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♦ Torque wrench - V.A.G 1331-

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♦ Dismantling and assembling device for valve cotters - VAS

5161-
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♦ Guide plate - VAS 5161/19B-

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– Unscrew spark plugs using spark plug socket and extension -
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3122 B- .
4. Valve gear 157

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- Edition 12.2017 orise nte
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– Screw guide plate - VAS 5161/19B-
s to cylinder head, as shown
s
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in illustration, using knurled screws - VAS 5161/12- .
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– Screw adapter - T40012- into spark plug thread.
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– Connect compressed air with pressure rating of at least 6 bar.

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– Strike tight valve cotters with drift - VAS 5161/3- and a plastic
com
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hammer.
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For inlet side

– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-
into centre thread of guide plate - VAS 5161/19B- .
– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS
5161/19B- .
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
For exhaust side

into outer thread of guide plate - VAS 5161/19B- .
– Press installation cartridge - VAS 5161/8- down and turn
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw backwards and forwards slightly. This
causes the valve cotters to be pressed apart and taken into
the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove assembly cartridge - VAS 5161/8- .

- Edition 12.2017
Volkswagen AG
– Pull off valve stem seals using valve stem seal puller
swa
g-en3364-
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– If valve stem seal puller - 3364- cannot be used on account of
at
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restricted space, drive out roll pin -arrow- with a drift and re‐
n
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move impact extractor attachment.

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– Place lower part of valve stem seal puller - 3364- onto valve
stem seal.
– Insert punch -1- into bore in lower part of puller.
– Place installation lever on puller and pull out valve stem seal
-arrow-.
4. Valve gear 159

- Edition 12.2017
Installing valve stem seals
Caution
Risk of damage when valve stem oil seals are being installed
♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem. olksw AG. V agen AG
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– Take out plastic sleeve.
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– Insert valve spring and valve spring plate.
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– Install removal and installation device for valve cotters - VAS
es, in part or in w
5161- as shown.
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Inlet side
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Exhaust side opyri
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- Edition 12.2017
AG. Volkswagen AG d
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♦ If the valve cotters have been removed from the a installation
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cartridge, they must first be inserted into the insertion device
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♦ Press assembly cartridge -VAS 5161/8- onto insertion device
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– Press installation cartridge - VAS 5161/8- down with pressure
hole
spec
fork - VAS 5161/2- , and turn installation cartridge knurled
es, in part or in w
screw back and forth whilst pulling upwards.
t to the co
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled
screw.
rrectness of i
– Remove removal and installation device - VAS 5161- .
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4.4.2 Removing and installing valve stem seals (cylinder head removed)
ion
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4. Valve gear 161

- Edition 12.2017
♦ Valve stem seal puller - 3364-

♦ Valve stem seal fitting tool - 3365-
♦ Dismantling and assembling device for valve cotters - VAS
5161-
♦ Guide plate - VAS 5161/19B-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
Removing valve stem oil seals
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
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– Bolt guide plate - VAS 5161/19B-ksw to cylinder head usinges not
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For inlet side

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into centre thread of guide plate - VAS 5161/19B- .
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– Insert assembly cartridge - VAS 5161/8- into guide plate - VAS

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5161/19B- .
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– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .

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Prote AG.

- Edition 12.2017
For exhaust side

into outer thread of guide plate - VAS 5161/19B- .
– Press installation cartridge - VAS 5161/8- down and turn
knurled screw of installation cartridge - VAS 5161/8- to right
until tips engage in valve cotters.
– Move knurled screw backwards and forwards slightly. This
causes the valve cotters to be pressed apart and taken into
the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Remove assembly cartridge - VAS 5161/8- .
– Pull off valve stem seals using. Vvalve

olkswastem
ge
seal puller - 3364- .
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Installing valve stem seals

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♦ Place plastic sleeve -A-, enclosed with new valve stem

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seals -B-, onto valve stem. C py
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– Lightly oil sealing lip of valve stem seal.
Prote AG.
– Push valve stem oil seal onto plastic sleeve.

– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
– Insert valve spring and valve spring plate.
– Remove removal and installation device for valve cotters -
VAS 5161- as shown.
4. Valve gear 163

- Edition 12.2017
Inlet side
Exhaust side
Note
♦ If the valve cotters have been removed from the installation

cartridge, they must first be inserted into the insertion device
- VAS 5161/18- . agen
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V gu
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– Press installation cartridge - VAS 5161/8- down with pressure
ce
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fork - VAS 5161/2- , and turn installation cartridge knurled

du
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screw back and forth whilst pulling upwards.

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– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled

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screw.
wit
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– Remove removal and installation device for valve cotters -

spec
VAS 5161- .
es, in part or in w
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rrectness of i
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Prote AG.

- Edition 12.2017
4.5 Removing and installing camshaft con‐

trol valve 1 - N205- / exhaust camshaft
control valve 1 - N318-
Removing
– Disconnect electrical connectors -1 and 3-.
– Remove exhaust camshaft control valve 1 - N205- , -item 4-
and exhaust camshaft control valve 1 - N318- s-itemn AG. Volkswagen AG do
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Install in reverse order of removal, observing
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Replace oil seals and O-rings.
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hole
– Lubricate sealing surfaces of oil seals to inlet camshaft control
spec
valve 1 - N205- / exhaust camshaft control valve 1 - N318- with
es, in part or in w
engine oil.
t to the co
Specified torques
rrectness of i
l purpos
4.6 Removing and installing actuator for

camshaft adjustment -N580- / -N605-
nform
mercia
a
Removing
com
tion in
– Disconnect connector -arrow- from respective actuator for
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camshaft adjustment -N580- / -N605- -2-.
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– Unscrew bolt -1-. cum

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– Carefully pull out actuator for camshaft adjustment.
Co
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Installing
rig ht
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Prote AG.
Note
♦ Moisten O-ring with engine oil.

♦ Check for damage.
♦ Not a replacement part, provided together with actuator for
camshaft adjustment
Specified torques
4. Valve gear 165

- Edition 12.2017
5 Inlet and exhaust valves

⇒ “5.1 Checking valve guides”, page 166
⇒ “5.2 Checking valves”, page 167
⇒ “5.3 Valve dimensions”, page 167
5.1 Checking valve guides

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
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Test sequence
wit
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– Insert valve in guide. Valve stem end must be flush with guide.
ole,
spec
On account of differing stem diameters, only use inlet valve in

inlet valve guide and exhaust valve in exhaust valve guide.

t to the co
– Determine rock.
Wear limit
rrectne
Inlet valve guide Exhaust valve guide

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0.80 mm 0.80 mm
cial p
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atio
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Note
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♦ If the wear limit is exceeded, repeat the measurement with

t
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new valves. If the wear limit is exceeded again, renew the cyl‐
pr
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♦ If the valve is to be renewed as part of a repair, use a new C py
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valve for the calculation. rig ht
py by
co Vo
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Prote AG.

- Edition 12.2017
5.2 Checking valves

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

Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
Dimension Inlet valve Outlet valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45
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5. Inlet and exhaust valves 167

- Edition 12.2017 AG. Volkswagen A
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17 – Lubrication
ed ran
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1 Sump, oil pump

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⇒ “1.1 Assembly overview - sump/oil pump”, page 168
ility
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⇒ “1.2 Removing and installing oil level and oil temperature send‐
is n
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er G266 ”, page 170
ole,
spec
⇒ “1.3 Removing and installing lower part of sump”, page 170
t to the co
⇒ “1.4 Removing and installing oil pump”, page 171
⇒ “1.5 Removing and installing upper part of sump”, page 174
rrectne
⇒ “1.6 Engine oil:”, page 177
s
1.1 Assembly overview - sump/oil pump
s o
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atio
Note
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If large quantities of swarf or metal particles (caused, for example, by partial seizure of the crankshaft or conrod
te
sd
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bearings) are found in the engine oil when performing repairs, thoroughly clean the oil passages, and renew
iv
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the engine oil cooler in order to prevent subsequent damage. cum

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1 - Nuts py by
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❑ 9 Nm cted agen
Prote AG.
2 - Oil level and oil temperature

sender - G266-
⇒ page 170
3 - Bolts
quence ⇒ page 170
❑ 8 Nm +90°
4 - Lower part of sump
❑ Plastic
⇒ page 170
5 - Plug
❑ Tighten sealing plug as
far as stop
6 - O-ring
❑ Lubricate O-ring with
engine oil
7 - Seal
8 - Baffle plate
9 - Bolts
❑ 4 Nm +45°
168 Rep. gr.17 - Lubrication

- Edition 12.2017
10 - Oil intake tube

❑ Clean strainer if soiled
11 - O-ring agen
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❑ Moisten
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12 - Oil
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13 - Centring sleeves
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14 - Upper part of sump
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15 - Bolt
es, in part or in w
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❑ 4 Nm +90°
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16 - Valve for oil pressure control - N428-
l purpos

17 - O-ring
nform
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ion
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18 - Drive chain for oil pump
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❑ Mark direction of rotation before removing.

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19 - Bolt
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21 - Cylinder block
agen
Prote AG.
22 - Bolts
23 - Bolts
❑ 8 Nm +90°
24 - Centring sleeve
25 - Bolts
❑ 4 Nm +45°
26 - Seal
1. Sump, oil pump 169

- Edition 12.2017
Plastic version of sump (bottom section) - tightening sequence

– Fit sump, and tighten bolts -1 … 20- in 2 stages in the se‐
quence shown:
Stage and tightening sequence Specified torque
1. Bolts -1- to -20- 8 Nm
2. Bolts -1- to -20- Turn 90° further
Tightening sequence for sump (top section)

– Tighten bolts -1 to 14- in the sequence shown.
Stage Tightening sequence and n AG. Volkswagen AG do
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1. Bolts -1- to -14- 8 Nm tho tee
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2. Bolts -1- and -2- Turn 180° further ss
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4. Bolt -10- Turn 180° further
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1.2 Removing and installing oil level and oil
spec
temperature sender - G266-
t to the co
Removing
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– Drain engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain‐
ing; Renewing oil filter and replenishing engine oil .
ss
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cial p
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– Unscrew nuts -3-, and remove oil level and oil temperature
mer
sender - G266- -1-.
atio
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– Renew seal.
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– Replenish engine oil and check oil level ⇒ Maintenance ; C py
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Booklet ; Engine oil: Draining; Renewing oil filter and replen‐ gh ht
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Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 168
1.3 Removing and installing lower part of

sump

- Edition 12.2017
♦ Used oil collector and extractor - V.A.G 1782-

♦ Safety glasses
♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA) olkswage es n
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Removing ir se
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tee
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– Remove noise insulation ⇒ General body repairs,
au exterior; ac
ss
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sulation .
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– Place used oil collection and extraction unit - V.A.G 1782- un‐
erm
ab
der engine, and drain engine oil ⇒ Maintenance ; Booklet ;
ility
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Engine oil: draining or extracting; Renewing oil filter and re‐
wit
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plenishing engine oil .
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Note
Please observe disposal instructions!
rrectness of i
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– Unscrew bolts -1 … 20-, and remove sump.

Installing
nform
ercia

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at
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i
Observe tightening sequence of bolts ⇒ page 170 .
on
c
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– Replenish engine oil and check oil level ⇒ Maintenance ;

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Booklet ; Engine oil: Draining; Renewing oil filter and replen‐ do

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Specified torques
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1.4 Removing and installing oil pump


- Edition 12.2017
Removing agen
AG. Volkswagen AG d
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– Remove sump (bottom section) ⇒ page 170 . d byV gu
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– Unscrew bolt -arrow-, and pull off baffle plate. ut
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- Edition 12.2017
– Pull spring of chain tensioner in -direction of arrow- using as‐

sembly tool - T10118- and secure it with locking pin - T40265- .
– Unscrew bolts -arrows- and remove oil pump.

Installing
– Check that both centring sleeves for centring oil pump are
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- Edition 12.2017
1.5 Removing and installing upper part of

sump
Removing
• Gearbox is removed.
– Remove rear sealing flange ⇒ page 55 .
– Remove oil pump ⇒ page 171 .
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– Remove sealant residue from sump (top section) using a ro‐

tating plastic brush, for example.
Note
Check timing chain cover for deformation. To do this, fit sump

upper part first without sealant and check gap between cover and
sump upper part. If deformation is evident and cover cannot be
aligned, renew cover after sump (top section) has been installed.
– Clean sealing surfaces. They must be free of oil and grease.

– Check oil galleries in sump upper part and crankcase for soil‐
ing.

2 mm).

- Edition 12.2017
Caution
Risk of lubrication system becoming clogged due to excess

sealant
♦ Do not apply sealant bead thicker than specified.

– Apply silicone sealant onto clean sealing surface of top section
of sump as illustrated -arrow-.
– Apply silicone sealant between cylinder block and lower timing

chain cover, as shown in illustration -arrows-.
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- Edition 12.2017
– Tighten new bolts -arrows-.

Bolts -arrows- 8 Nm +45°
– Install rear sealing flange ⇒ page 55 .
– Install oil pump ⇒ page 171 .
– Insert new baffle plate and bolt it on.
– Install bottom section of sump ⇒ page 170 .
ishing engine oil .
Specified torques
1.6 Engine oil:

Oil capacity:
With oil filter, 5.7 l
Engine oil specifications:
♦ ⇒ Maintenance ; Booklet 36.1 ; Service tables
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- Edition 12.2017
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Prote AG.

- Edition 12.2017
2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 179
⇒ “2.2 Removing and installing engine oil cooler”, page 179
⇒ “2.3 Removing and installing mechanical switching valve”, page
180
2.1 Assembly overview - engine oil cooler
⇒ page 42
2 - Seal
3 - O-ring
4 - Mechanical switching valve
5 - Engine oil cooler
❑ Observe notes
⇒ page 168
⇒ page 179
6 - Seal
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179
Prote AG.
2. Engine oil cooler
- Edition 12.2017
Removing
– Remove bracket for ancillaries ⇒ page 42 .
– Unscrew bolts -4 and 5-, and remove engine oil cooler -3- to‐
gether with gasket -2-.
Installing
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♦ Renew gaskets and seals.

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2.3 Removing and installing mechanical

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- Edition 12.2017
– Remove mechanical switching valve -1- from ancillary bracket

-arrow-.
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2. Engine oil cooler 181

- Edition 12.2017
3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 182 olks
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⇒ page 183
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9 - Bolt
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to ensure it is screwed
into old thread. Then,
tighten bolt to specified torque.
❑ 9 Nm

- Edition 12.2017
Tightening sequence - oil separator

– Tighten bolts in the sequence -1 … 7-.
3.2 Removing and

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- Edition 12.2017 ss
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⇒ “4.5 Removing and installing oil pressure switch F1 ”,

page 187
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2 - Seal
3 - Oil filter
⇒ Maintenance ; Book‐
let ; Engine oil: Drain‐
ing; Renewing oil filter
and replenishing engine
oil .
4 - O-ring
5 - Oil filter housing
❑ 25 Nm
6 - Oil drain connection
7 - O-ring
❑ Not available as re‐
placement part, sup‐
plied together with
⇒ Item 6 (page 184)
8 - Bolt
❑ Specified torque and
tightening sequence
⇒ page 40

- Edition 12.2017
4.2 Exploded view - oil pressure switches/oil pressure control
1 - Bolt
❑ 4 Nm +90°
2 - Valve for oil pressure con‐
trol - N428-
⇒ page 186
3 - O-ring
4 - O-ring
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❑ Checking ⇒ Vehicle di‐
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⇒ page 187
❑ 20 Nm nform
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12 - Stage 3 oil pressure switch - F447-

❑ 20 Nm
4. Oil filter, oil pressure switch 185

- Edition 12.2017
Installation position of stage 3 oil pressure switch - F447- -2-
Note
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Renewing oil filter and replenishing engine oil .
Specified torques
♦ ⇒ “4.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 185
4.4 Removing and installing oil pressure

regulating valve - N428-

- Edition 12.2017
♦ Used oil collector and extractor - V.A.G 1782-
Removing
– Remove poly V-belt ⇒ page 41 .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
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-3-.
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- Edition 12.2017
Note
♦ Place a cloth underneath ancillary bracket to catch any es‐

caping engine oil.
♦ Since the seal cannot be renewed individually, the oil pressure
switch needs to be renewed following removal.
– Separate electrical connector -arrow- on oil pressure switch -

F1- .
– Unscrew oil pressure switch -1-.
Installing
Note
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Specified torques
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- Edition 12.2017
– Separate electrical connector -arrow- on oil pressure switch

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Since the seal cannot be renewed individually, the oil pressure

Removing
sulation .

- Edition 12.2017
– Free electrical wiring harnesses -1- and -2- from fittings and
lay them to one side.
– Loosen hose clip -arrow-, and remove charge air hose -A-
– Separate connector -1- from stage 3 oil pressure switch -

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ole,
spec

t to the co
Note
rrectne
Screw new stage 3 oil pressure switch - F447- immediately into

s
bore to avoid loss of oil.

s o
cial p
f inform

mer

atio
om
n
c
Specified torques
i
or
n thi
te
sd
a

iv
o
r
trol”, page 185

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
♦ Noise insulation; Assembly overview - noise insulation ⇒ gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

- Edition 12.2017
4.8 Checking oil pressure

⇒ “4.8.1 Checking engine oil pressure”, page 191
⇒ “4.8.2 Checking oil pressure for piston spray jets”, page 192
4.8.1 Checking engine oil pressure

♦ Oil pressure tester - V.A.G 1342- n AG. Volkswagen AG do
lkswage es n
o ot g
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tho
u or
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nl
pt
du
an
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
Conditions for testing
rrectness of i
• Oil level OK.
l purpos
• Engine oil temperature at least 80°C (radiator fan must have

run once)
nform
ercia
Note
m
at
om
ion
c
in t
r
♦ The oil pump is regulated and has 2 pressure levels. The

o
his
e
pressure levels are checked subsequently.

at
do
priv
cum
or
♦ During the run-in period or emergency running mode of the

f
en
g
engine the oil pump operates only at high pressure level.

n
t.
yi Co
Cop py
♦ The oil pressure depends on the engine oil temperature. At an
t. rig
gh ht
yri by
engine oil temperature of 80°C the mean value must be at‐ cop Vo
by lksw
tained approximately. cted agen
Prote AG.
Test sequence
Note

caping engine oil.
– Remove oil pressure switch for reduced oil pressure - F378-

⇒ page 188 .
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of the oil pressure switch.
– Screw oil pressure switch for reduced oil pressure - F378- into
oil pressure tester - V.A.G 1342- .
– Connect oil pressure tester to earth.
– Start engine, and check oil pressure at the specified engine
speed levels.
• Oil pressure at idling speed: 0.85 to 1.6 bar

- Edition 12.2017
• Oil pressure at 2000 rpm: 1.2 to 1.6 bar

– Switch off engine.
insulation .
– Disconnect connector -1- from valve for oil pressure control -
N428- . Unclip cable and route it towards bottom to prevent it
from being trapped in the belt drive. With disconnected con‐
nector the oil pump operates at high pressure level.
– Start engine, and check oil pressure at the specified engine
speed levels.
• Oil pressure at idling speed: 0.85 to 4.0 bar
Installing
– Install oil pressure switch.
– Fit connector to valve for oil pressure control - N428- . Route
cable carefully.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation
– Read event memory of engine control unit, and clear all entries
⇒ Vehicle diagnostic tester.
Specified torques
trol”, page 185 wage
e ks s no
Vol t gu
d by ara
4.8.2 Checking oil pressure for piston spray
e nte
ris
tho eo
jets au ra
ss c
ce
le
un
pt

an
d
itte
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♦ Oil pressure tester - V.A.G 1342-

erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
o
pr
cum
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fo
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
♦ Test instrument/DSO adapter - VASa5571-

gen AG
. Volkswagen AG
do
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Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
ss
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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h re
ole,
spec
t to the co
Conditions for testing
rrectne
• Oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
ss
run once)
o
cial p
f inform
Test sequence
mer
atio
– Remove stage 3 oil pressure switch - F447- ⇒ page 189 .
om
n
c
i
or
n
– Screw stage 3 oil pressure switch - F447- into oil pressure
thi
te
sd
tester - V.A.G 1342- .
iva
o
pr
cum
r
– Screw in oil pressure tester - V.A.G 1342- in place of oil pres‐

fo
en
ng
sure switch.
t.
yi Co
Cop py
t. rig
– Connect test instrument/DSO adapter (2-pin) - VAS 5571- to yri
gh by
ht
oil pressure switch cop Vo
by lksw
cted agen
Prote
– Connect connector for stage 3 oil pressure switch - F447- to
AG.
test instrument/DSO adapter (2-pin) - VAS 5571- .

– Check oil pressure; stage 3 oil pressure switch F447
Installing
– Install oil pressure switch.
Specified torques
trol”, page 185

n AG. Volkswchain drive,
agen AG generation III) Volkswagen R GmbH
wage does
- Edition 12.2017 y Volks not
g b ua
ed ran
oris tee
th or
19 – Cooling
au ac
ss
ce
e
nl
pt
du
an
itte
y li
1 Cooling system/coolant
erm
ab
ility
⇒ “1.1 Connection diagram - coolant hoses”, page 194 ot p
wit
, is n
h re
⇒ “1.2 Draining and adding coolant”, page 198
hole
spec
es, in part or in w
⇒ “1.3 Checking cooling system for leaks”, page 203
t to the co
⇒ “1.4 Flushing cooling system”, page 204
⇒ “1.5 Flushing cooling system, quick reference guide”,
rrectness of i
page 224
l purpos
1.1 Connection diagram - coolant hoses
nform
ercia
⇒ “1.1.1 Vehicles with dual clutch gearbox”, page 194

m
at
⇒ “1.1.2 Vehicles with manual gearbox”, page 196
om
ion
c
in t
r
1.1.1 Vehicles with dual clutch gearbox

o
his
ate
do
priv
cum
for
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Note
n
t.
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Cop py
t. rig
gh
♦ Blue = large coolant circuit.
ht
pyri by
Vo
co lksw
by
♦ Red = small coolant circuit.
cted agen
Prote AG.
♦ Brown = heater circuit.

♦ Yellow = gear oil cooling circuit.
♦ The arrows point in the direction of coolant flow.
194 Rep. gr.19 - Cooling

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Golf 2013 ➤ , Golf 2015d➤ by , Golf 2017 ➤ , Golf Variant 2014
Vo ot g
ua➤ , Golf V ...
ran
horise
chain drive, generation III) Volkswagen teeR GmbH
t or
au - Edition 12.2017
ac
ss
ce
e
nl
1 - Auxiliary radiator
pt
du
an
itte
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❑ Location: in front right
erm
ab
wheel housing
ility
ot p
wit
, is n
h re
⇒ page 252
hole
spec
es, in part or in w
⇒ page 254
t to the co
2 - Radiator outlet coolant tem‐
perature sender - G83-
rrectness of i
⇒ page 231 l purpos
⇒ page 242
nf
ercia
orm
3 - Actuator for engine temper‐
m
atio
m
ature regulation - N493-

o
n in
or c
4 - Cylinder head/cylinder
thi
te
sd
a
block
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rp
cu
❑ Renew coolant after re‐
o
m
f
en
ng
placing
t.
yi Co
op py
t. C rig
gh ht
yri
⇒ page 113 p by
co Vo
by lksw
cted agen
Prote AG.
⇒ page 115
5 - Restrictor
6 - Coolant expansion tank
7 - Cap for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 204
8 - Non-return valve
9 - Exhaust manifold
10 - Exhaust turbocharger
11 - Heat exchanger for heater
❑ Renew coolant after replacing
12 - Restrictor
14 - Auxiliary pump for heating - V488-
15 - Radiator outlet coolant - G62-
16 - Coolant shut-off valve - N82-
17 - Coolant pump
1. Cooling system/coolant 195

- Edition 12.2017
AG. Volkswagen AG d
18 - Restrictor ksw
agen oes
not
Vol
y gu
19 - Coolant shut-off valve - N82- ise
d b ara
nte
or eo
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20 - Gear oil cooler s aut ra
c
s
ce
le
un
pt
an
d
❑ Fitting location: front left wheel housing
itte
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rm
ab
❑ Assembly overview ⇒ page 252 pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
23 - Radiator for engine coolant
t to the co
rrectness of i
l purpos
1.1.2 Vehicles with manual gearbox
nform
mercia
a
com
tion in
Note
r
te o
thi
s
iva
do
♦ Blue = large coolant circuit.
r
rp
cum
fo
en
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♦ Red = small coolant circuit.

n
t.
yi Co
Cop py
♦ Brown = heater circuit.
t. rig
gh ht
pyri by
Vo
o
♦ Yellow = gear oil cooling circuit.
c by lksw
cted agen
Prote AG.
♦ The arrows point in the direction of coolant flow.

- Edition 12.2017
. Volkswagen AG
gen AG does
1 - Auxiliary radiator Vol
ksw
a
not
y gu
❑ Location: in front right rised b ara
nte
wheel housing tho eo
au ra
❑ Assembly overview s s c
ce
le
⇒ page 252
un
pt
an
d
itte
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erm
⇒ page 254
ab
ility
ot p
wit
is n
h re
ole,
spec
⇒ page 231
t to the co
⇒ page 242
rrectne
3 - Actuator for engine temper‐
ature regulation - N493-
ss
4 - Cylinder head/cylinder
o
cial p
f i
block
nform
mer
atio
placing
om
n
c
i
or
n thi
e
⇒ page 113
t
sd
iva
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pr
c
um
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fo
⇒ page 115
en
ng
t.
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op
5 - Restrictor
C py
t. rig
gh ht
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6 - Coolant expansion tank cop Vo
by lksw
cted agen
Prote AG.
7 - Cap for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 204
9 - Exhaust manifold
11 - Heat exchanger for heater
12 - Restrictor
14 - Auxiliary pump for heating - V488-
16 - Coolant shut-off valve - N82-
17 - Coolant pump

- Edition 12.2017
18 - Restrictor
1.2 Draining and adding coolant

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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♦ Refractometer - T10007 A-
orm
m
atio

om
n in
or c
♦ Hose clamp pliers - VAS 6340-

thi
te
sd
iva
♦ Coolant system charge unit - VAS 6096-

o
r
rp
cu
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m
f
en
ng
♦ Adapter for cooling system tester - V.A.G 1274/8-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
Draining
WARNING

Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

sulation .
– Place drip tray for workshop hoist - VAS 6208- underneath.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
an
itte
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– Lift retaining clip -2-, pull off connection, and drain coolant.
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
Vehicles with dual clutch gearbox:

m
atio
om
n in
– Also release retaining clips -1 and 2-. Disconnect coolant ho‐

or c
thi
ses leading to auxiliary radiator on left, and drain coolant.

te
sd
iva
o
r
Continued for all:

rp
cu
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f
en
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Filling
t.
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Cop py
t. rig
gh ht
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Caution cop Vo
by lksw
cted agen
Prote AG.
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

- Edition 12.2017
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, only ever use 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.
♦ Use ONLY refractometer - T10007A- 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, n AG. Volkswagen AG do
swage es n
the cooling effect will be impaired. byV
olk ot g
ua
d ran
ir se
♦ Do not reduce the coolant concentration by adding water even
tho tee
or
in warmer seasons and in warmer countries. Frost protection
ss
au ac
must be guaranteed down to at least -25°C.
ce
e
nl
pt
du
♦ Read off anti-freeze figures for respective replenished coolant
an
itte
y li
additives.
erm
ab
ility
ot p
♦ The temperature read off the refractometer - T10007A- corre‐
wit
, is n
sponds the »ice flocculation point«. Flakes of ice may start
h re
forming in the coolant at this temperature.
hole
spec
es, in part or in w
♦ Never reuse old coolant.
t to the co
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
rrectness of i
Coolant mixture ratio

l purpos
• Coolant (40%) and distilled water (60%) for frost protection to

-25°C
nform
ercia
• Coolant (50%) and distilled water (50%) for frost protection to

m
at
om
-36°C
on
c
in t
or
• Coolant: ⇒ Electronic parts catalogue (ETKA) .

his
ate
do
riv
– Re-connect coolant hoses.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
– Fill coolant expansion tank of -VAS 6096- with 10 litres of pre-

mixed coolant in correct mixture ratio; mixture ratio
⇒ page 200 .
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Feed vent hose -1- into a small container -2-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -3- to compressed air.
• Pressure: 6 to 10 bar.
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition, and select following menu options on ⇒ Ve‐
hicle diagnostic tester:
♦ Guided Functions
♦ 01 - Engine electronics
♦ 01 - Fill/bleed cooling system
AG. Volkswagen AG d
agen oes
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d b ara
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tho eo
au ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
201
Prote AG.
1. Cooling system/coolant
. Volkswagen AG
gen AG does
swa
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 y V ➤ , Golf V ...
olk not
gu
b a
rised
drive, generation III) Volkswagen RraGmbH nte
o eo
- Edition 12.2017 aut
h
ra
ss c
ce
e
– Open valve -B-; turn lever in direction of flow to do this.
nl
pt
du
an
itte
y li
• The suction-jet pump reduces pressure in the cooling system
erm
ab
to below atmospheric pressure. The needle on the gauge
ility
ot p
should move into the green zone.
wit
, is n
h re
– Also briefly open valve -A- (turn lever in direction of flow to do
hole
spec
this) so that hose on coolant expansion tank of cooling system
es, in part or in w
charge unit -VAS 6096- fills with coolant.
t to the co
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
rrectness of i
• The suction-jet pump will continue generating a vacuum in the
l purpos
cooling system. The needle on the gauge must remain in the
green zone.
nf
ercia
o
– Close valve -B-.
rm
m
atio
m
– Pull off compressed air hose.
o
n in
or c
thi
• The needle on the gauge must stay in the green zone. The low
te
sd
iva
pressure in the cooling system is then sufficient for subse‐
o
r
rp
cu
quent filling.
o
m
f
en
ng
t.
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Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
♦ If the needle does not reach the green zone, repeat the proc‐ Prote AG.
ess.
♦ If the vacuum drops, the cooling system must be checked for
leaks.
– Open valve -A- slowly.

• The vacuum in the cooling system causes the coolant to be
drawn out of the coolant expansion tank of -VAS 6096- ; the
cooling system is then filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.
– Fill coolant up to max. mark.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Run engine at idling speed until both large coolant hoses on
radiator are heated up.
– Switch off engine and let it cool off.

- Edition 12.2017
– Check coolant level.

• When the engine is cold, the coolant level must be between
the min. and the max. marks.
• The coolant level may be at the max. marking when the engine
is warm.
– Fill more coolant if necessary.
1.3 Checking cooling system for leaks

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e

at
do
priv

um
for
en
ng
t.
yi
♦ Cooling system tester - V.A.G 1274 B-
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

- Edition 12.2017
Procedure
• Engine at operating temperature.
WARNING

– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.0 bar using hand pump of cool‐
ing system tester.
– If this pressure is not maintained, locate and rectify leaks.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Check pressure relief valve in cap.
– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto coolant filler cap.
rrectness of i
– Build up pressure using hand pump of cooling system tester.
l purpos
• The pressure relief valve must open at a pressure of 1.6 to

1.8 bar.
nform
ercia
– Renew filler cap, if pressure relief valve does not open as de‐
m
a
com
scribed.
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
1.4 Flushing cooling system

t.
yi Co
Cop py
t. rig
gh
In the event of any of the following conditions, the cooling system
ht
pyri by
Vo
o
must be flushed: by c lksw
cted agen
Prote AG.
♦ The coolant is extremely discoloured or has lost its colour.
♦ The coolant has an unnatural or unusual smell.
♦ Particles are visible in the coolant.
♦ Heavy deposits have formed in the coolant expansion tank.

- Edition 12.2017
Note
♦ The coolant must be drained before the system is flushed. gen AG

. Volkswagen AG
does
Then the cooling system must be filled with distilled water. Volkswa not
gu
y
db ara
♦ The cooling system is flushed with 20 l of distilled water.
or Then,
ise nte
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the distilled water is replaced by coolant (mixture ratio
au
th 50:50). ra
ss c
♦ Never reuse old coolant.
ce
e
nl
pt
du
an
♦ For a quick reference guide, refer to ⇒ page 224 . The quick
itte
y li
erm
reference guide contains the basic steps of the workflow. It
ab
ility
might be helpful to print out the guide and tick off the corre‐
ot p
wit
sponding work steps after having performed them.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- Edition 12.2017

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Coolant flushing and filling device - VAS 531 007-

♦ Test adapter - VAS 691 005/5-
♦ Suction-jet pump from cooling system charge unit - VAS 6096-
♦ Refractometer - T10007 A-
♦ Compressed air connection with 6 … 10 bar(g)

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♦ Assembly tool - T10118- aut or
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Schematic overview of coolant flushing and filling device - VAS
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531 007- :
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1 - Container with distilled wa‐
ot
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❑ Fill with 30 l of distilled
spec
water
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t to the co
2 - Container with coolant
❑ Fill with 30 l of coolant
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❑ Frost protection down to
approx. -36°C
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3 - Empty container
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❑ For used coolant

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4 - Empty container
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❑ For used coolant
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sight class with a nylon
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7 - Pump
❑ Cut-out pressure
approx. 1.5 bar
8 - Valve block
❑ With pressure gauge
and shut-off taps
9 - Drain hose
❑ Connected to valve
block for releasing pres‐
sure
10 - Flushing hose
❑ Connected to breather
hose of coolant expansion tank for flushing
❑ Comes from connection 1 on sight glass
❑ Seal with plugs when not in use
11 - Plug
12 - Hose clamps
❑ Qty. 4
13 - Cleaning adapter
❑ Approx. 15 cm in length
❑ For cleaning coolant flushing and filling device after flushing
❑ Connected between valve block and flushing hose ⇒ Item 10 (page 207)
14 - Extraction adapter
❑ Approx. 100 cm in length
❑ Connected to suction hose ⇒ Item 5 (page 207) for extracting coolant

- Edition 12.2017
Procedure:
– With coolant hose pulled off, pour approximately 1 litre of dis‐
tilled water into the coolant expansion tank.
– Drain coolant into drip tray .
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– Re-connect detached coolant hoses. lksw
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– Fill container »1« with 30 l of distilled water. aut ra
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– Fill container »2« with 30 l of coolant. Mixture ratio is 50:50 for
nl
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frost protection down to approx. -36°C.
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– Empty containers »3« and »4«.
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– Remove valve block from plug-in connector on equipment trol‐
, is n
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ley.
hole
spec
– Connect coolant flushing and filling device - VAS 531 007- to
es, in part or in w
t to the co
battery.
Bleeding coolant flushing and filling device - VAS 531 007- :
rrectness of i
– Connect suction hose -A- to container »1« with distilled water.
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– Connect drain hose -arrow- to plug-in connector -B- on valve
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- Edition 12.2017
– Close shut-off taps -A- and -B-.
Note
Do not fit the valve block onto the test adapter - VAS 691 005/5-
yet. The filler hose must be bled first.
– Switch on pump for -VAS 531 007- .

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– Open cut-off tap -A-. Volksw
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– Open shut-off tap -B- briefly to bleed filler hose. orise nte
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– Close shut-off taps -A- and -B-. ss a c
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Connecting coolant flushing and filling device - VAS 531 007- :
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– Screw test adapter -2- ( -VAS 691 005/5- ) onto coolant ex‐
pansion tank -1-.
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ate
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– Pull drain hose -arrow- off plug-in connector -B- on valve block.

- Edition 12.2017 olksw AG. V agen AG
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– Fit valve block -1- onto test adapter
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– Connect suction-jet pump -2- from -VAS 6096- to plug-in con‐
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nector -B- on valve block -1-.
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Filling cooling system with distilled water:
op Vo
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- Edition 12.2017
n AG do
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– Place end of vent hose -8- of suction-jet pump into a container.

– Connect compressed air hose -6- to suction-jet pump -7-.
– Open shut-off tap -B- on valve block -5-.
• The suction-jet pump reduces pressure in the cooling system
to below atmospheric pressure. The pointer of the pressure
gauge must fall to at least -0.85 bar.
– Close shut-off tap -B-.
– Pull off compressed air hose -6-.
– Observe pressure gauge. The pointer of the pressure gauge
must remain stationary at -0.85 bar at least. The vacuum in
the cooling system is then sufficient for subsequent filling.
Note
♦ If the vacuum drops, the cooling system must be checked for leaks.
♦ The vacuum that builds up depends on the pressure in the compressed air system.

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- Edition 12.2017
s
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• The pump of the -VAS 531 007- must be switched on.
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– »Slowly« open shut-off tap -A-.
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• The vacuum in the cooling system causes the distilled water
h re
hole
to be drawn into the cooling system, and thus causes the cool‐
spec
ing system to be filled. In addition, the pump of the -VAS 531
es, in part or in w
007- feeds distilled water into the coolant expansion tank.
t to the co
– Fill cooling system until pressure of approx. 1 bar can be read
off gauge.
rrectness of i
After filling, the pressure in the coolant expansion tank must be
l purpos
released. Proceed as follows to do this:

– Close shut-off tap -A- after filling.
nform
mercia
a
– Remove suction-jet pump -2- from valve block -1- .
com
tion in
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– Connect drain hose -arrow- to plug-in connector. Open shut-

off tap -B-, and leave it open so that the pressure in the cooling
system releases.

– With ignition switched off, release and pull off electrical con‐
nector -1- on engine temperature sender - G62- -3-.
Note
If the connector of the coolant temperature sender - G62- is pulled

off, the actuator for engine temperature regulation - N493- will
open and the radiator fan will start to operate as soon as the en‐
gine is started.
– Temporarily, install air filter housing so that corresponding lo‐

cation on cylinder head remains free. Air filter housing can be
placed on battery, for example.
– Start engine and increase speed for approximately 1 minute.
Then, switch off engine.

- Edition 12.2017
Flushing cooling system with distilled water:

• Shut-off tap -A- is closed; shut-off tap -B- is open.
– Remove breather hose -2- from coolant expansion tank -1- .
– Connect breather hose -2- from coolant expansion tank to

flushing hose -1-.
– Seal connection on coolant expansion tank using plug -3-. Se‐
cure plug with a hose clip.
– Close shut-off tap -B-.
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♦ Flushing oris of the cooling system will now begin. Please
nte
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th
fillslevel
au of the tanks in order to assure correct flushing r a capaci‐
c
ties.
s
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♦ The engine is running at idling speed during the entire flushing

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process.
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– Start engine and allow to idle.

wit
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– Set heater temperature to “HI”.

spec
es, in part or in w
– Switch off air conditioner compressor. To do this, press AC

t to the co
button.
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1 - Flushing cylinder block with distilled water:

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Prote AG.

- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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pt
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– Clamp off breather hoses for heat exchanger and cylinder

head with hose clamps.
– Open shut-off tap -A- on valve block.
• Pump approx. 9 litres of distilled water through engine.
– Close shut-off tap -A-.
2 - Flushing cylinder head with distilled water:

- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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co lksw
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cted agen
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– Clamp off breather hoses for heat exchanger and radiator with
hose clamps.
3. Flushing heat exchanger for heater with distilled water:

- Edition 12.2017
lkswage es n
o ot g
byV ua
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ir se tee
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– Clamp off breather hoses for radiator and cylinder head with
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4. Flushing entire cooling system

– Remove any hose clamps.
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- Edition 12.2017
Flushing cooling system with coolant

– Connect suction hose -A- to container -2- for coolant.
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Prote AG.
– Clamp off breather hoses for heat exchanger and cylinder

head with hose clamps.
• Pump approx. 5 litres of coolant through engine.
2 - Flushing cylinder head with coolant:

- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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c
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Vo
co lksw
by
cted agen
Prote AG.
– Clamp off breather hoses for heat exchanger and radiator with
hose clamps.
3. Flushing heat exchanger for heater with coolant:

- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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– Clamp off breather hoses for radiator and cylinderauthead with
h eo
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hose clamps. ss c ce
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4. Flushing entire cooling system

ole,
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– Remove any hose clamps.

t to the co

rrectne

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1. Cooling system/coolant
agen
Prote AG.
- Edition 12.2017
The flushing process is now completed. Switch off the pump, and
switch off the engine.
Removing coolant flushing and filling device - VAS 531 007- :
– Open shut-off tap -B-, and leave it open so that the pressure
in the cooling system releases.
– Pull plug -3- off coolant expansion tank, and reconnect breath‐
er hose -2-.
– Use plug to seal flushing hose -1-.
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– Remove valve block -1- and
utho test adapter -2-. eo
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– If anti-freeze protection down to approx. -36°C is required, s
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drain coolant expansion tank empty, and fill it with coolant

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The coolant flushing and filling device - VAS 531 007- can be used
es, in part or in w
for extracting coolant ⇒ page 221 .
t to the co
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– The coolant level must be at the »weld seam« -arrow-.
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tion in
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– Reattach electrical connector -1- on coolant temperature
sender - G62- -3-.
– Install air filter housing at its final installation position.
– Separating the connectors caused entries to be stored in the
event memory of the engine control unit. Clear event memory
– Tighten cap of coolant expansion tank until it engages.
– Then run engine at idling speed until radiator fan cuts in.
Check coolant level and frost protection
– If the frost protection is not sufficient, extract coolant from
coolant expansion tank. Set correct frost protection by filling
more coolant concentrate.
– After each time coolant concentrate has been filled, run engine
at increased engine speed for about 2 minutes, and check frost
protection again.

- Edition 12.2017
• 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.
• When the engine is at operating temperature, the coolant level
must be at the »weld seam« -arrow-.
• When the engine is cold, the coolant level must be approx.
5 mm above the max. marking -arrow-.
Note
. Volkswagen AG
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This excessive amount of coolant level is necessary since theVolkswa not
coolant level may decrease automatically due to bleedingeproc‐
db
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Extracting coolant:
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
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co lksw
by
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- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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un
pt
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ility
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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te
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Prote AG.
Note
Use the extraction adapter ⇒ Item 14 (page 207) (14) for extracting the coolant.
– Detach suction hose -5- from container -2-.

– Fit extraction adapter -12- onto plug-in connector of suction
hose -5-.
– Switch on pump -7-, and open shut-off taps -A- and -B- on
valve block -8-.
– Use extraction adapter -12- to extract any excess coolant.
– Close shut-off taps on valve block, and switch off pump.
Cleaning coolant flushing and filling device - VAS 531 007- :

- Edition 12.2017
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
ss c ce
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pt
du
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ility
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es, in part or in w
t to the co
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♦ If coolant remains in the sight glass for longer periods of time, the sight glass may become opaque. There‐
o
m
f
en
ng
fore, the sight glass must be flushed with distilled water after the flushing procedure has been completed.
t.
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♦ If the sight glass is opaque, it must be cleaned with a nylon brush.
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♦ Use cleaning adapter ⇒ Item 13 (page 207) (13) for flushing.
by c lksw
cted agen
Prote AG.
– Connect suction hose -5- to container -1- for distilled water.

– Fit flushing hose -10- onto cleaning adapter -9-. Fit cleaning
adapter -9- to plug-in connector -B- on valve block -8-.
– Open shut-off valves -A- and -B- on valve block -8-.
– Switch on pump -7-, and pump distilled water through hoses
until coolant has been flushed out of sight glass -6-.
– Switch off pump, and close shut-off taps.
– Remove cleaning adapter, and seal flushing hose with plug.

- Edition 12.2017
1.5 Flushing cooling system, quick refer‐

ence guide
Note
The quick reference guide contains the basic steps of the work‐
flow. It might be helpful to print out the guide and tick off the
corresponding work steps after having performed them. For a de‐
tailed description of the necessary work steps, refer to
⇒ page 204 .
Step Measure Volume of flush‐

ing medium
1 Draining coolant ---
2 Fill cooling system with distilled water ---
3 Pull connector off coolant temperature sender - G62- ---
4 Run engine at idling speed ---
5 Clamp off breather hose for heat exchanger -1- and cylinder head -2-; flush cooling 9 l of distilled wa‐
system ter
6 Clamp off breather hose for heat exchanger -1- and radiator -3-; flush cooling sys‐ 2 l of distilled wa‐
tem ter
7 Clamp off breather hose for cylinder head -2- and radiator -3-; flush cooling system 2 l of distilled wa‐
wagen AG
. Volkswagen AG
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8 Remove all clamps; dflush by cooling system t gu
ara 6 l of distilled wa‐
e
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9 Clamp off breather
ss
a hose for heat exchanger -1- and cylinder head c -2-; flush cooling 5 l of coolant
system
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10 Clamp off breather hose for heat exchanger -1- and radiator -3-; flush cooling sys‐ 5 l of coolant
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11 Clamp off breather hose for cylinder head -2- and radiator -3-; flush cooling system 2 l of coolant
wit
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12 Remove all clamps; flush cooling system 6 l of coolant

h re
ole,
spec
13 Switch off engine ---

t to the co
14 Drain coolant expansion tank empty, and fill with coolant concentrate ---
15 Fit connector of coolant temperature sender - G62- ---
16 Run engine until radiator fan starts to operate. ---
rrectne
17 Check frost protection ---

ss o
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f inform
mer
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by
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Prote AG.

- Edition 12.2017
1 - Breather hose of heat ex‐

changer for heater unit
2 - Breather hose for cylinder
head
3 - Breather hose of radiator for
engine coolant
AG. Volkswagen AG d
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- Edition 12.2017
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 226
⇒ “2.2 Assembly overview - electric coolant pump”, page 228
⇒ “2.3 Assembly overview - coolant temperature sender”,
page 231
⇒ “2.4 Removing and installing toothed belt for coolant pump”,
page 231
⇒ “2.5 Removing and installing coolant pump”, page 233
⇒ “2.6 Removing and installing auxiliary pump for heating V488
”, page 235
⇒ “2.7 Removing and installing coolant shut-off valve N82 ”, page
236
⇒ “2.8 Removing and installing coolant valve for gearbox N488 ”,
page 238
⇒ “2.9 Removing and installing actuator for engine temperature
regulation N493 ”, page 239
⇒ “2.10 Removing and installing coolant temperature sender G62
”, page 241
⇒ “2.11 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 242
2.1 Assembly overview - coolant pump, thermostat
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10 - Toothed belt guard
11 - Bolt
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12 - Toothed belt drive sprocket
❑ Observe installation position
13 - Oil seal for balance shaft, inlet side
14 - Balancer shaft
15 - Seal
16 - Bolt
❑ 9 Nm
17 - Union
18 - Spring
19 - Seal
20 - Actuator for engine temperature regulation - N493-
2. Coolant pump, regulation of cooling system 227

- Edition 12.2017
Actuator for engine temperature regulation - N493- – tightening

sequence
– Tighten bolts in the sequence -1 to 5-.
Coolant pump - tightening sequence

– Tighten bolts for coolant pump in the sequence -1 … 4-.
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Coolant valve for gearbox - N488- , vehicles with dual clutch

gearbox

- Edition 12.2017
1 - Bolt
❑ 9 Nm
2 - Coolant hose
3 - Nut
❑ 9 Nm
4 - Coolant hose
5 - Coolant valve for gearbox -
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2.4 Removing and installing toothed belt for

coolant pump
♦ Insert tool - T10360-
Removing

- Edition 12.2017

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– Lift retaining clip -1-, detach upper coolant connection and

push it to one side.

- Edition 12.2017
– Separate electrical connector -1- on oil pressure switch -2-.

– Unscrew bolts -arrows- and remove toothed belt guard.
Caution
Risk of damage to the thread

♦ The drive sprocket bolt has a left-hand thread.
– Loosen bolt on drive sprocket -1- for coolant pump using tor‐
que wrench - V.A.G 1410- and insert tool - T10360- , and
unscrew it by 3 turns. Counterhold at vibration damper when
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– Disconnect connectors -2, 3 and 4-. Unscrew securing bolts

-1-, and lay bracket to one side.
– Unscrew bolts -1 … 4-, and detach coolant pump from actuator

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- Edition 12.2017
2.6 Removing and installing auxiliary pump

for heating - V488-
♦ Hose clamps to 25 mm - 3094-
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♦ ⇒ “2.2 Assembly overview - electric coolant pump”,
page 228
2.7 Removing and installing coolant shut-off

valve - N82-

- Edition 12.2017
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Installing
Note
– Check coolant level ⇒ page 203 .

Specified torques
page 228

- Edition 12.2017
2.8 Removing and installing coolant valve

for gearbox - N488-
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- Edition 12.2017

– Clamp off coolant hoses on coolant valve for gearbox - N488-
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2.9 Removing and installing actuator for en‐

gine temperature regulation - N493-
The engine temperature regulation module - GX33- comprises
the following components:
♦ Actuator for engine temperature regulation - N493-
♦ Position sender for engine temperature regulation - G1004-
Removing
– Remove coolant pump ⇒ page 233 .
– Remove throttle valve module - GX3- ⇒ page 294 .

- Edition 12.2017
– Unscrew coolant pipe from intake manifold -arrows-.
– Lift retaining clips -1- and disconnect coolant hoses.
– Pull connector -1- off actuator for engine temperature

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- Edition 12.2017
– Moisten new O-rings -4- with coolant.

– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push actuator for engine temperature regulation - N493- -3-
onto connecting piece and centring pins in cylinder block.
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– Remove bolt -1- and press air pipe (left-side) towards left
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- Edition 12.2017
Note
♦ Use a cloth to catch the escaping coolant.

♦ Insert new coolant temperature sender - G62- immediately in‐
to union to avoid loss of coolant.
– Remove bolt -2- and detach coolant temperature sender -

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- Edition 12.2017
– Disconnect connector -4-, and pull out retaining clip -3-.

– Pull out radiator outlet coolant temperature sender - G83- -1-
with O-ring -2-.
Note
♦ Use a cloth to catch the escaping coolant.

♦ Insert new coolant temperature sender - G83- immediately in‐
to screw connection at radiator outlet to avoid loss of coolant.
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- Edition 12.2017
3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 244
⇒ “3.2 Removing and installing coolant pipe at front of engine”,
page 244
⇒ “3.3 Removing and installing coolant pipe on top of engine”,
page 246
⇒ “3.4 Removing and installing coolant pipe on radiator cowl”,
page 247
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3.2 Removing and installing coolant pipe at

front of engine

- Edition 12.2017

lkswage es n
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– Release fasteners -arrows- and detach air duct (top section)
-1-.
3. Coolant pipes 245

- Edition 12.2017 en AG. V
olkswagen AG
ag does
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by ara
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– Clamp off coolant hoses -1 and 2- with hose clamps, up to
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Co
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Note

Specified torques
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 244
3.3 Removing and installing coolant pipe on

top of engine

- Edition 12.2017
♦ Spring-type clip pliers - VAS 6362- n AG. Volkswagen AG do

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Removing
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– Remove Ignition coil with output stage for cylinder “3”
⇒ page 347 .
l purpos
– Release fasteners -arrows- and detach wiring duct -1- from

bracket.
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– Clamp off coolant hoses -arrows- with hose clamps up to

25 mm - 3094- .
– Release hose clips and detach coolant hoses.
– Unscrew bolt -1- and remove coolant pipe (top).
Installing
Note

Specified torques
3.4 Removing and installing coolant pipe on

radiator cowl

- Edition 12.2017
Removing
AG. Volkswagen AG d
agen oes
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Prote AG.
Rep. gr.19 - Cooling
- Edition 12.2017

– Seal coolant hoses with hose clamps up to 25 mm - 3094- .
Note

– Unscrew bolts -2-, and remove coolant pipe -1-.
Installing
Install in reverse order of removal,
agen observing theAG
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- Edition 12.2017
4 Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 250
⇒ “4.2 Assembly overview - radiator cowl and radiator fan”, page
251
⇒ “4.3 Assembly overview - auxiliary radiator”, page 252
⇒ “4.4 Removing and installing radiator”, page 252
⇒ “4.5 Removing and installing auxiliary radiator”, page 254
⇒ “4.6 Removing and installing radiator cowl”, page 256
⇒ “4.7 Removing and installing radiator fan”, page 258
4.1 Assembly overview - radiator/radiator fan
1 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 251
2 - O-ring
AG. Volkswagen AG d
❑ Moisten with coolant agen oes
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3 - Radiator outlet coolant tem‐ ris ed
nte
perature sender - G83- ut
ho eo
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⇒ page 242
nl
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⇒ page 252
es, in part or in w
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5 - Coolant hose
❑ Pull out retaining clip to
remove
rrectness of i
❑ Connect ⇒ page 251

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6 - O-ring
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7 - Charge air cooler

n
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⇒ page 270
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❑ For radiator Prote AG.
11 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
12 - Rubber mounting
❑ For charge air cooler.

- Edition 12.2017
13 - O-ring
14 - Retaining clip
❑ For radiator outlet coolant temperature sender - G83- .
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert it into coolant hose.
– Push coolant hose onto coolant pipe -1- until it audibly engag‐
es.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
AG. Volkswagen AG d
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4.2 Assembly overview - radiator cowl and radiator fan
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1 - Bolt
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2 - Radiator cowl
spec
es, in part or in w
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⇒ page 256
3 - Bolt
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❑ 5 Nm
l purpos
4 - Radiator fan - V7-

nf
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⇒ page 258
orm
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5 - Radiator fan 2 - V177- atio

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⇒ page 258
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4. Radiator, radiator fan 251

- Edition 12.2017
4.3 Assembly overview - auxiliary radiator
AG. Volkswagen AG d
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♦ On vehicles with manual gearbox,
orise the auxiliary radiator is in‐ nte
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stalled on the front rightsside.
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♦ Vehicles with dual clutch gearbox are equipped with 2 auxiliary
ce
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radiators – on the front right and front left sides.
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⇒ page 254
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4 - Hose retainer
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6 - Hose clamps
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11 - Air duct
12 - Rubber grommet
13 - Support
14 - Bolt
❑ 3.5 Nm
4.4 Removing and installing radiator

Removing
– Remove radiator grille ⇒ General body repairs, exterior; Rep.
gr. 66 ; Radiator grille/front panel; Removing and installing
radiator grille .

- Edition 12.2017

– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.
– If fitted, remove centre guide profile -A- from lock carrier

-arrows-.
AG. Volkswagen AG d
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– Unclip air ducts -1- on both sides from lock carrier -2-
es, in part or in w
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-arrow-.
– To do this, release catches -3- in -direction of arrow-, and pull
off air ducts. Disregard arrows below.
rrectness of i
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tion in
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- Edition 12.2017
– Working through opening in lock carrier, press locking tabs for

radiator on left and right -1-. Press radiator off charge air cool‐
er.
– Swing radiator towards engine, and lift it out of charge air
cooler mountings. Remove radiator downwards.
Installing
Note
♦ If there are minor dents in the fins, refer to repair instructions

⇒ page 8 .
♦ Renew O-rings.
♦ If the radiator has been renewed, the entire coolant must be
renewed.
– Install radiator cowl ⇒ page 256 .

– Connect coolant hose with plug-in connector ⇒ page 251 .
– Install radiator grille ⇒ General body repairs, exterior; Rep.
gr. 66 ; Radiator grille/front trim; Removing and installing ra‐
diator grille .
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 250
Lock carrier bolts 5 Nm
4.5 Removing and installing auxiliary radia‐

tor lksw
agen
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254
cop Vo
by lksw
Rep. gr.19 - Cooling Prote
cted AG.
agen
- Edition 12.2017
Note
♦ On vehicles with manual gearbox, the auxiliary radiator is in‐

stalled on the front right side.
♦ Vehicles with dual clutch gearbox are equipped with 2 auxiliary
radiators – on the front right and front left sides.
Removing
– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Wheel change .
– Remove front part of right wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner;
AG. Volksw agen ARemoving
agen G do
and installing front wheel housing
Vo lksw liner . es n
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Auxiliary radiator, right-side
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– Separate electrical
ss connector -arrow-.
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Continued for all vehicles

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Place a cloth underneath to catch escaping coolant.

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Prote AG.

- Edition 12.2017
Auxiliary radiator, left-side

. Volkswagen AG
a gen AG does
– Clamp off coolant hoses using hose clamps, up to 25 mmVol -
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– Loosen hose clamps -1- and pull off coolant hoses.
au
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– Move coolant hose on retainer to one side. To do so, release
ce
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nl
pt
fasteners -arrows A-, and pull off -arrows B-.
du
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co Vo
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by
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– Loosen hose clamps -1- and pull off coolant hoses.
– Remove auxiliary radiator together with bracket.
Continued for all vehicles

– Pull off air guide -1- in -direction of arrow-.
– Remove auxiliary radiator -2- from bracket -3-.
Installing
– Bleed cooling system ⇒ page 198 .
Specified torques
♦ ⇒ “4.3 Assembly overview - auxiliary radiator”, page 252
4.6 Removing and installing radiator cowl

Removing

- Edition 12.2017
WARNING
Danger of injury; the radiator fans can run at any time.

♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl. en AG. V
olkswagen AG
wag does
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– Release coolant pipe -1- from radiator cowlthoby
ris unscrewing nte
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bolts -2-. au ra
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– Loosen hose clips -arrows-, and remove charge air hose -A-.
l purpos
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– Separate connector -1- for radiator fan. To do this, push lock‐ Prote AG.
ing tab in direction of arrow -A-, and press release mechanism.
– Simultaneously press locking tabs on left and right of radiator
cowling -arrow B-. Pull radiator cowl upwards off radiator, and
remove it downwards.
Installing
Specified torques

- Edition 12.2017
4.7 Removing and installing radiator fan

⇒ “4.7.1 Removing and installing radiator fan V7 ”, page 258
⇒ “4.7.2 Removing and installing radiator fan V177 ”, page 258
4.7.1 Removing and installing radiator fan -

V7-
Removing
Note
Fit all cable ties in the original position when installing.

– Separate electrical connector -arrow-.
– Unscrew bolts -1- and remove radiator fan - V7- .
Installing
Install in reverse order of removal,
agenobserving theAfollowing:
AG. Volkswagen G d
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olks ot g
– Install radiator cowled⇒bypage
V
256 . ua
ran
ris tee
Specified torquesautho or
ac
ss
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
ce
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nl
pt
page 251
du
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4.7.2 Removing and installing radiator fan -

, is n
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V177-
spec
es, in part or in w
t to the co
Removing
rrectness of i
Note
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Fit all cable ties in the original position when installing.

nf
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– Separate electrical connector -arrow-.

om
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t.
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– Install radiator cowl ⇒ page 256 . t. C rig
gh ht
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Specified torques
co lksw
by
cted agen
Prote AG.
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 251

- Edition 12.2017
21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 259
⇒ “1.2 Removing and installing turbocharger”, page 262
⇒ “1.3 Adjusting charge pressure positioner V465 ”, page 266
1.1 Assembly overview - turbocharger

Part I
Part II ⇒ page 260
1 - O-ring
❑ Renew after removal AG. Volkswagen AG d
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2 - Bolt rise tee
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❑ 9 Nm au ac
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3 - Coolant supply line

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4 - O-ring
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h re
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spec
5 - Seal

t to the co
6 - Nut
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❑ 25 Nm
ss
o
cial p
f i

nform
⇒ page 262
mer
atio
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8 - Oil supply line

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9 - Heat shield
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10 - Bolt
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❑ 9 Nm
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12 - Bolt
❑ 9 Nm
13 - O-ring
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
1. Exhaust turbocharger 259

- Edition 12.2017
16 - Connection
17 - O-ring
18 - Bolt
❑ 9 Nm
Part II
Part I ⇒ page 259
1 - Bolt
❑ 9 Nm
2 - Oil return line
3 - O-ring
4 - Bolt
❑ 10 Nm
5 - Charge air pressure con‐
troller - V465-
❑ Adjusting ⇒ page 266 AG. Volkswagen AG d
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10 - Bolt
es, in part or in w
t to the co
❑ 9 Nm
11 - Turbocharger air recircu‐
lation valve - N249-
rrectness of i
❑ Note installation posi‐

l purpos
tion ⇒ page 261

12 - O-ring
nf
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⇒ page 262
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15 - Bolt
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Prote AG.
❑ 9 Nm
16 - Bolt
❑ 9 Nm
260 Rep. gr.21 - Turbocharging/supercharging

- Edition 12.2017
17 - Bolt
❑ 9 Nm
18 - Coolant return line
19 - O-ring
❑ Moisten with coolant AG. Volkswagen AG d
agen oes
lksw not
20 - O-ring d byV
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❑ Renew after removal horis
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❑ Moisten with engine oil. ss a c
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21 - Bolt
pt
du
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❑ Coat thread with high-temperature paste ⇒ Electronic parts catalogue (ETKA) .
erm
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❑ 30 Nm
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22 - Bracket
h re
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❑ For turbocharger
spec
es, in part or in w
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23 - Bolt
❑ 30 Nm
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24 - Bolt
❑ 9 Nm
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Installation location of turbocharger air recirculation valve - N249-

m
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ion
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rig ht
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Prote AG.

- Edition 12.2017
1.2 Removing and installing turbocharger
Special tools and workshop agen

AG. Volkswagen AG d
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equipment required olksw not
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by
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Prote AG.
♦ Tensioning strap - T10038-


- Edition 12.2017
Caution
If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just renew
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
♦ Check air filter housing, air filterAGelement
. Volkswagand
en AGair inlet ho‐
ses for contamination. olkswagen does
no
V t gu
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♦ Check the wholerischarge
ed air path and charge air cooler for
ara
nte
foreign objects.
ut
ho eo
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sa ac
♦ If foreign objects
s
are discovered in the charge air system,
ce
le
clean the charge air path and, if necessary, renew the

un
pt
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charge air cooler.

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♦ Risk of functional impairment due to soiling – observe
ility
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rules for cleanliness ⇒ page 7 .
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spec
Removing
t to the co
rrectne
⇒ page 339 .
– Remove air filter housing and intake hose ⇒ page 287 .
ss o
cial p
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inform
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– Unscrew bolt -1-, and pull air pipe off turbocharger.

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– Pull off coolant hose -arrow-.

– Pull off connectors -1- and -2-. Open retainer -3-.

- Edition 12.2017
– Unscrew bolt -1- for earth wire, and pull off coolant hoses
-2 and 3-.
– Pull off connector -arrows-.
– Release fastener -arrow-, and remove wiring duct -4- upwards

from retainer.
– Unscrew bolts -1, 2 and 3-. Swivel coolant pipe to one side.
– Remove Lambda probe 1 before catalytic converter - GX10-
⇒ page 322 .
– Remove actuators for camshaft adjustment ⇒ page 165 .
G. Volkswagen nA AG do
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– Removing ignition coils with outputystages
Vol
ks ⇒ page 347 . ot g
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– Unscrew bolts -arrows- and nut -1-.
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– Remove heat shield -2-.
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– Remove bolt -1- and loosen bolt -3-.

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– Remove bracket -2- for turbocharger.

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- Edition 12.2017
– Disconnect electrical connectors -1 and 3-.

hose.
– If necessary, detach head protection from lines and hoses.
– Unscrew bolts -1-, and pull off connecting piece.

. Volkswagen AG
gen AG d
– Unscrew bolts ol-2
kswand 3-, and pull off oil supply
a oes
not line and oil
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– Loosen
au hose clip -arrow-.
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The following procedure is necessary to provide more space be‐

ot
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tween the cylinder head and plenum chamber bulkhead.

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spec
es, in part or in w
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– Unscrew bolts -1, 2 and 3-, and remove pendulum support.

rrectness of i
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– Pull engine back approx. 20 mm with tensioning strap -
. Cop py
T10038- .
ht rig
rig ht
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- Edition 12.2017

– Remove turbocharger from cylinder head, and remove it up‐
wards.
Installing
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Lubricate turbocharger studs with high-temperature paste. For
high-temperature, paste refer to ⇒ Electronic parts catalogue
(ETKA) .
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
(same as original equipment) ⇒ Electronic parts catalogue
(ETKA) .
– Install front exhaust pipe with catalytic converter

⇒ page 339 .
G. Volkswagen AG d
– Align exhaust system free of stress ⇒ page
lksw
335
agenA . oes
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– Add coolant ⇒ page 199 . sedb ara
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– Check oil level. aut ra
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Note
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After installing turbocharger, run engine for about 1 minute at

ot
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idling speed. Do not rev up immediately to ensure that the turbo‐

h re
charger is fully primed with oil.

hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i

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♦ ⇒ “7.1 Assembly overview - Lambda probe”, page 321

nform
mercia
1.3 Adjusting charge pressure positioner -

a
com
tion in
V465-
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Cop py
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Prote AG.

- Edition 12.2017
♦ Torque wrench - VAS 6854-
♦ Setting gauge - T40346-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
♦ Open-end spanner ris insert (10 mm) - V.A.G 1783/1-
ed
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ility
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spec
es, in part or in w
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♦ Open-jaw spanner (5 mm)

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nf
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Procedure
orm
m
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

atio
om
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -

n in
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noise insulation .
thi
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– Release clip -1- for catalytic converter -2-.

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– Push clip -1- onto turbocharger.

t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.

- Edition 12.2017
– Unscrew nuts -2- from catalytic converter -1-.
lkswage es n
o ot g
byV ua
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tho
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ss
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spec
es, in part or in w
– Lay catalytic converter aside slightly.
t to the co
– Select the following menu item on ⇒ Vehicle diagnostic tester:
♦ 0001 - Adjust charge pressure positioner V465
rrectness of i
– Follow instructions on ⇒ Vehicle diagnostic tester.
l purpos
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– Insert setting gauge - T40346- .

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– Loosen lock nut -1-. t. C rig
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– Adjust linkage -arrow -of charge pressure positioner - V465-
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cted
according to instructions on ⇒ Vehicle diagnostic tester.
agen
Prote AG.
– Tighten lock nut -1- to specified torque.

– Remove setting gauge - T40346- .
Specified torques

- Edition 12.2017
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 269
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 270
⇒ “2.3 Removing and installing charge air cooler”, page 270
⇒ “2.4 Removing and installing charge pressure sender G31 ”,
page 271
⇒ “2.5 Checking charge air system for leaks”, page 272
2.1 Assembly overview - charge air system
Note
♦ Installing screw-type clips for charge air hose connections ⇒ page 270 .
♦ Before carrying out tests or repairs, check all air pipes and air hoses to make sure they are firmly seated
and not leaking.
♦ Observe rules for cleanliness ⇒ page 7 .
1 - Air intake pipe

2 - Grommet
3 - Spacer sleeve agen
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4 - Bolt d by V gu
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❑ 7 Nm uthor eo
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5 - Air intake hose s
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6 - Air duct
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7 - Charge air cooler
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hole
spec
⇒ page 270
es, in part or in w
t to the co
Note
In the event of minor dents in the fins

rrectness of i
⇒ page 8
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8 - Air duct
nform
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9 - Rubber mounting
m

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10 - Rubber mounting
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11 - Bolt
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❑ 7 Nm
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13 - Grommet
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Prote AG.
14 - Bolt
❑ 5 Nm
2. Charge air system 269

- Edition 12.2017 gen AG
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d
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15 - Charge air pressure sender - G31-ised b ara
nte
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❑ Removing and installing ⇒ page ho
ut 271
eo
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16 - O-ring
ce
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17 - Air intake hose
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18 - Air intake pipe
spec
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2.2 Assembly overview - charge-air hose
connections
rrectne
Fitting hose connections with fluted union
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Caution
form
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The screw-type clips -A- on the charge air pipes must be tight‐
o
n
c
ened to 5.5 Nm. If the torque is too low or too high, the charge
i
or
n thi
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air hose may slip off the charge air pipe during vehicle opera‐
t
sd
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tion.
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Prote AG.
♦ Check all air hoses and pipes to make sure they are firmly
seated and not leaking before carrying out tests or repairs.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ In order to be able to securely attach the air ducts on their
connections, the screws of the used hose clips have to be
sprayed with penetrating spray before installing.
2.3 Removing and installing charge air cool‐

er

- Edition 12.2017
Removing
sulation .
– Release hose clips -1 and 2-, and remove air intake hose.
– Removing radiator ⇒ page 252 .
AG. Volkswagen AG d
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– Have a second mechanic release retaining clips -1- on left and s
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right in direction of arrow -A-. Remove condenser -3- upwards

nl
pt
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from mountings -arrows B-.
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– Secure condenser to lock carrier.
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– Take out charge air cooler from underneath.
h re
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Installing
spec
es, in part or in w
t to the co
rrectness of i
Note
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♦ In the event of minor dents in the fins ⇒ page 8

♦ Hose connections as well as hoses for charge air system must
nform
ercia
be free of oil and grease when installing.

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ion
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♦ To ensure that the charge air hoses can be properly secured

a
do
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at their connections, spray rust remover onto the worm thread

p
cum
or
of used hose clips before installing.

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Specified torques: gh ht
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♦ ⇒ “2.1 Assembly overview - charge air system”, page 269 Prote
cted AG.
agen
2.4 Removing and installing charge pres‐

sure sender - G31-
Removing
sulation .

- Edition 12.2017

– Unscrew bolts -1-, and pull charge pressure sender - G31- out
of air pipe.
Installing
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 269
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
AG. Volkswagen AG d
agen oes
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♦ Ultrasonic testers - V.A.G 1842-
s c
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Procedure
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itte
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– Release hose clips -1 and 2-, and remove air pipe.

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– Connect adapter - V.A.G 1687/10- with adapter -V.A.G

form
mer
1687/14- to turbocharger.
atio
om
– Connect charge air system tester - V.A.G 1687- to adapter.

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Prote AG.

- Edition 12.2017
Prepare charge air system tester - V.A.G 1687- as follows:

– Completely unscrew pressure regulating valve -2-, close
valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- to com‐

pressed air -1- via commercial adapter.
Note
If there is water in the inspection glass, drain it via the drain plug
-6-.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary,
adjust pressure to 0.5 bar.
. Volkswagen AG
gen AG
– Check charge air system for leaks by hearing, touching,
Vol
ksw with
a does
not
commercially available leak detector spray or eusing
db
y ultrasonic gu
ara
tester - V.A.G 1842- . ho
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Note
un
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♦ A small amount of air escapes through the valves and enters
pe
ility
the engine. Therefore a holding pressure test is not possible.

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wit
, is n
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♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating

hole
instructions
spec
es, in part or in w
t to the co
♦ Before removing the adapter, release pressure in the test cir‐

cuit by pulling off hose coupling.
rrectness of i
Installing
l purpos
Assemble in reverse order of dismantling.

nform
mercia
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tion in
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t.
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Cop py
t. rig
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co lksw
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Prote AG.

- Edition 12.2017
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 274 . Volkswage n AG n AG d
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⇒ “1.2 Releasing high pressurey Vinolkfuel
s system”, page 284 not
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1.1 Overview hoof fitting locations - injection
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Components A to H are not shown in the exploded view.
an
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1 - Inlet camshaft control valve
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wit
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1 - N205-
h re
hole
❑ Fitting location
spec
⇒ page 82
es, in part or in w
t to the co
⇒ page 165
rrectness of i
2 - Exhaust camshaft control
valve 1 - N318-
l purpos
⇒ page 82
nform
ercia

m
⇒ page 165
a
com
tion in
3 - Actuators for camshaft ad‐
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justment
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❑ Exhaust cam actuator B

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rp
cum
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for cylinder 1 - N581-

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❑ Exhaust cam actuator A Cop py
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❑ Exhaust cam actuator A
co Vo
by lksw
cted
agen
Prote AG.

⇒ page 281
4 - Lambda probe 1 after cata‐
lytic converter - GX7-
❑ Consisting of
Lambda probe after catalytic converter - G130-
274 Rep. gr.24 - Mixture preparation - injection

- Edition 12.2017
Lambda probe 1 heater after catalytic converter - Z29-

❑ Fitting location ⇒ page 284
5 - Lambda probe 1 before catalytic converter - GX10-
❑ Consisting of
Lambda probe - G39-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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t to the co
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cial p
f inform
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Prote AG.
1. Injection system 275

- Edition 12.2017
Lambda probe heater - Z19-

6 - Turbocharger air recirculation valve - N249- and charge pressure positioner - V465-
❑ Components fitted directly on turbocharger
. Volkswagen AG
gen AG does
7 - Hall sender 3 - G300- olks
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❑ Fitting location ⇒ page 283 ris
ed
b ara
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❑ Removing and installing ⇒ page 349 aut ra
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❑ 9 Nm
ce
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nl
pt
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8 - High-pressure pump with fuel pressure regulating valve - N276-
itte
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❑ Assembly overview - high-pressure pump ⇒ page 316 .
wit
, is n
h re
hole
spec
9 - Connectors
es, in part or in w
t to the co
❑ For Lambda probe 1 before catalytic converter - GX10- .
❑ For Lambda probe 1 after catalytic converter - GX7- .
rrectness of i
l purpos
10 - Brake light switch - F- and brake pedal switch - F47-

nf
ercia
❑ Removing and installing ⇒ Brake system; Rep. gr. 45 ; Overview of fitting locations; Overview of fitting
or
locations - ABS/ESP .
m
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om
n in
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thi
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❑ 9 Nm
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t.
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op py
❑ Fitting location ⇒ page 231 t. C rig
gh ht
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❑ Removing and installing ⇒ page 241 cop Vo
by lksw
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Prote
13 - Engine (motor) control unit - J623-
AG.

14 - Ignition coils with output stages
15 - Vacuum unit for air flow control flaps (intake manifold flaps)
16 - Intake manifold flap air flow control valve - N316-
17 - Engine speed sender - G28-
❑ Oil seal
❑ Renew bolt
❑ 4 Nm and turn 45° further

- Edition 12.2017
18 - Electrical connectors for

❑ Knock sensor 1 - G61- . Volkswagen AG
gen AG
waflap d
❑ Intake manifold olks valve - N316- oes not g
byV ua
❑ Fuel rpressure
ise
d sender - G247- ran
tee
ho
❑ Intake
aut manifold flap potentiometer - G336- or
ac
ss
❑ Hall sender - G40-
ce
e
nl
pt
du
❑ Injectors (combustion chamber) N30 to N33
an
itte
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ab
ility
ot p
19 - Fuel pressure sender for low-pressure - G410-
wit
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❑ Fuel pressure sender for low pressure - G410- must be installed using adapter.
hole
spec
es, in part or in w
t to the co
❑ 15 Nm
rrectness of i
20 - Knock sensor 1 - G61-
❑ To remove, coolant pump must be removed together with thermostat.
l purpos
nf
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21 - Intake manifold sender - GX9-
orm
m
❑ Consisting of
atio
om
n in
c
Intake air temperature sender - G42-

or
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te
sd
iva
Intake manifold pressure sender - G71-

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22 - Throttle valve module - GX3- cop Vo
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❑ Consisting of Prote AG.
Throttle valve drive for electronic power control - G186-
Throttle valve drive angle sender 1 for electronic power control - G187-

- Edition 12.2017
Throttle valve drive angle sender 2 for electronic power control - G188-
❑ After throttle valve module - GX3- has been renewed, or after it has been removed and then reinstalled,
it must be adapted to engine control unit - J623- ⇒ Vehicle diagnostic tester.
23 - Activated charcoal filter solenoid valve 1 - N80-
24 - Fuel pressure sender - G247-
❑ 27 Nm
25 - Intake manifold flap potentiometer - G336-
26 - Valve for oil pressure control - N428-
AG. Volkswagen AG d
agen oes
27 - Radiator outlet coolant temperature sender - G83- Vol
ksw not
gu
by ara
❑ Fitting location ⇒ page 231 ris
ed
nte
tho eo
❑ Removing and installing ⇒ page 242 sa
u ra
c
s
28 - Charge air pressure sender - G31-
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
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29 - Oil pressure switch - F1- , oil pressure switch for reduced oil pressure - F378- and piston cooling jet control
, is n
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valve - N522-
hole
spec
es, in part or in w
t to the co
rrectness of i
A - Injectors, direct injection
l purpos
❑ No. 1 cyl. injector - N30-
nform
ercia

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at
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io
❑ No. 4 cyl. injector - N33- n
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or

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ate
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B - Injectors, intake manifold injection

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for
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❑ Injector 2 for cylinder 1 - N532-
C py
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co Vo
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cted
agen
Prote AG.

C - Fuel pump control unit - J538-
❑ Removing and installing ⇒ Rep. gr. 20 ; Fuel pump
D - Clutch position sender - G476-
❑ Only fitted to vehicles with a manual gearbox
E - Gas pedal module - GX2-
❑ Consisting of
Acceleration pedal position sender - G79-

- Edition 12.2017
Accelerator position sender 2 - G185-Volkswa

AG. gen AG
agen do
❑ Fitting location ⇒ page 279 olks
w es n
ot g
byV ua
ir se
d
⇒ Rep. gr. 20 ; Accelerator mechanism
ran
te
ho eo
ut
F - Radiator fan control
ss unit - J293-
a ra
c
❑ Installed in radiator fan.
ce
e
nl
pt
du
an
itte
G - Stage 3 oil pressure switch - F447-
y li
erm
ab
ility
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❑ Testing, removing and installing ⇒ page 188 .
, is n
h re
hole
H - Left electrohydraulic engine mounting solenoid valve - N144- and right electrohydraulic engine mounting
spec
solenoid valve - N145-
es, in part or in w
t to the co
❑ Only installed on selected vehicles (depending on gearbox)
rrectness of i
Accelerator pedal module - GX2-
l purpos
1- Securing element for accelerator pedal module
nf
ercia
2- Electrical connector
orm
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3- Gas pedal module - GX2-
atio
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Brake light switch - F- / brake pedal switch - F63- and vacuum Prote AG.
sender - G608-
1- Brake light switch - F- / brake pedal switch - F63-
2- Vacuum sender - G608-
♦ On brake servo in engine compartment

- Edition 12.2017
Clutch position sender - G476-

• On mounting bracket for clutch pedal -arrow-
Removing and installing ⇒ Rep. gr. 30 ; Clutch mechanism
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Fuel pump control unit - J538-
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2- Fuel pump control unit - J538-
atio
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3- Electrical connector
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- Edition 12.2017
Ignition coils and actuators

1 - Ignition coil 1 with output stage - N70-
6 - Exhaust cam actuator B for cylinder 1 - N581-
7 - Exhaust cam actuator A for cylinder 1 - N580-
14 - Activated charcoal filter solenoid valve 1 - N80-
Injectors (combustion chamber)

1 - No. 1 cyl. injector - N30-
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Intake manifold injectors utho eo
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1 - Injector 2 for cylinder 1 - N532- s
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2 - Injector 2 for cylinder 2 - N533-

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281
AG.
1. Injection system
- Edition 12.2017 . Volkswage AG n AG d
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1 - Fuel supply line tho eo
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2 - Coolant line
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3 - Connector for injectors (intake manifold) itte
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1 - Vacuum unit for air flow control flaps (intake manifold flaps)
2 - Intake manifold flap air flow control valve - N316-
Intake manifold flap potentiometer - G336- -1-

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- Edition 12.2017
AG. V agen AG
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Electrical connectors db
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1 - For injectors (combustion chamber).
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2 - For knock sensor 1 - G61- .
s
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pt
3 - Stage 3 oil pressure switch - F447-
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4 - For intake manifold flap valve - N316- , fuel pressure sender -
pe
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G247- , intake manifold flap potentiometer - G336- , coolant
ot
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temperature sender - G62- and Hall sender - G40- .
h re
hole
spec
es, in part or in w
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High-pressure pump and Hall sender
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2 - Fuel pressure regulating valve - N276-
nform
ercia
3 - Fuel supply line leading to fuel rail for injectors (intake mani‐
fold)
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tion in
4 - Fuel supply line to fuel rail of direct injectors
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5 - Fuel pressurisation line from fuel tank
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Engine speed sender - G28- -1-
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Lambda probes
1 - Connector for Lambda probe 1 after catalytic converter - GX7-
2 - Connector for Lambda probe 1 before catalytic converter -
GX10-

- Edition 12.2017
Lambda probe 1 before catalytic converter - GX10- -1-
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Lambda probe 1 after catalytic converter - GX7- -1-
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1.2 Releasing high pressure in fuel system

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• Release high pressure. cted agen
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Releasing high pressure in fuel system:

– Switch on ignition, and select following menu options on ⇒ Ve‐
hicle diagnostic tester:
♦ 01 - Engine electronics
♦ Guided Functions
♦ 01 - Release high pressure in fuel system
• The fuel pressure will drop to the specified value.
– Switch off ignition.
The fuel rail is still filled with fuel but the fuel is no longer under
high pressure.

- Edition 12.2017
WARNING
The fuel system is pressurised.

♦ Danger of injury caused by fuel spray.
• Wear protective goggles.
• Wear protective gloves.
• To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
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– Open the high-pressure system immediately after pressure d by V in ua
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the high pressure fuel system has been released. oWrapir se a tee
clean cloth around the connection before openingau it. Catch the
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pressure will rise again due to reheating effects.
hole
spec
♦ The ignition must now not be switched on as switching the
es, in part or in w
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ignition on would cause pressure to rise again.
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drive, generation III) Volkswagen R GmbH eo
ut
- Edition 12.2017 ss a ra
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2 Air filter
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⇒ “2.1 Assembly overview - air filter housing”, page 286
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⇒ “2.2 Removing and installing air filter housing”, page 287
hole
spec
2.1 Assembly overview - air filter housing
es, in part or in w
t to the co
1 - Air duct (bottom section)
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❑ On lock carrier.
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2 - Air duct (top section)
❑ On lock carrier.
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3 - Cover
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❑ For air duct
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4 - Bolt
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8 - Air intake hose
9 - Spring-type clip
10 - Bolts
❑ 1.5 Nm
11 - Air filter upper part
❑ Remove dirt, leaves and
salt residues
12 - Air filter element
❑ Use only genuine air fil‐
ter elements ⇒ Elec‐
tronic parts catalogue
(ETKA) .
let 36.1 ; Air filter: clean‐
ing housing and renew‐
ing filter cartridge
let 43.1 ; Air filter: cleaning housing and renewing filter cartridge
13 - Application
❑ For air filter lower part
14 - Air filter lower part
❑ Remove dirt, leaves and salt residues
15 - Bump stop
16 - O-ring
17 - Water drain hose
❑ With valve
❑ Cleaning

- Edition 12.2017
18 - Air duct
❑ On air cleaner (bottom section)
2.2 Removing and installing air filter hous‐

ing AG. Volkswagen
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– Unscrew ise
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– Release
ss catch -arrow- and detach cover -2-.
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– Release catches -arrows-, and remove air duct (top section)
l purpos
-1-.
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– Detach vacuum hose -1-.
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– Release hose clip -2- and detach air hose.
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– Carefully take out air cleaner housing -3-.

Installing
Note
♦ Use a silicone-free lubricant to install the air hose.

– Check air intake hose for salt residue, dirt and leaves (clean
air side).
– Check intake port for dirt as far as the air filter element.
– Install air filter housing.
Note
Make sure to route the water drain hose in a straight line down‐
wards, without kinks.
2. Air filter 287

- Edition 12.2017
3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 288
⇒ “3.2 Removing and installing intake manifold”, page 289
⇒ “3.3 Removing and installing throttle valve module GX3 ”, page
294
⇒ “3.4 Cleaning throttle valve module ”, page 296
3.1 Assembly overview - intake manifold
1 - Bolt
❑ 20 Nm
2 - Support for intake manifold
3 - Nut
❑ 10 Nm
4 - Bonded rubber bush
❑ 5 Nm
5 - Bolt
❑ 7 Nm agen
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es, in part or in w
tion) - G188- .
t to the co
❑ After removing, instal‐
ling or renewing the
throttle valve module -
rrectness of i
J338- it always must be
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gine control unit - J623-
⇒ Vehicle diagnostic
nf
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tester.
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⇒ page 289
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9 - Intake manifold flap potentiometer - G336-
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10 - Ball stud Prote
cted AG.
agen

❑ 5 Nm
11 - O-ring
12 - Bolt
❑ 2.5 Nm

- Edition 12.2017
13 - Intake air temperature sender - G42- / intake manifold pressure sender - G71- .
14 - Bolt
❑ Tighten in several stages and in diagonal sequence
❑ Qty. 8
❑ 9 Nm
15 - Ball stud
❑ 5 Nm
16 - Bracket
❑ For electrical connector.
17 - Bolt
❑ 5 Nm
18 - Nut
❑ Tighten in several stages and in diagonal sequence
❑ Qty. 2
❑ 9 Nm
19 - Seal
20 - Vacuum hose
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22 - Vacuum hose rised
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23 - Bracket ss a ra
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❑ For electrical connectors.
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24 - Bolt
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❑ 5 Nm
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3.2 Removing and installing intake manifold
es, in part or in w
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♦ Insert tool - T10347-
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After intake manifold has been removed or renewed, intake mani‐ co Vo
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fold flap potentiometer - G336- must be adapted to engine control
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unit - J623- .
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
3. Intake manifold 289

- Edition 12.2017


– Remove noise insulation -1- A⇒ General
G. Volkswagebody
n AG d repairs, exterior;
agen
Rep. gr. 66 ; Noiseolinsulation; Assembly overview not - noise in‐
oes
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– Pull connector -1- off charge pressure sender - G31- .

t to the co

– Loosen hose clip -2- on air hose and pull air hose downwards
rrectness of i
off throttle valve module - GX3- .

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nf
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Prote AG.
– Separate electrical connectors -1, 2, and 3- underneath intake

manifold.

- Edition 12.2017
– Disconnect fuel supply hose -1- from intake manifold.

– Pull connector -3- out of retainer.
– Pull off connectors -4 and 5-.
– Free fuel rail wiring harness from fittings and lay it to one side.
– Disconnect connector and vacuum hoses from intake manifold

flap valve -1-.
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es, in part or in w
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nform
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at
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ion
– Loosen hose clip -arrow-, and remove left charge air hose
c
in t
or
-1- downwards, together with air pipe.

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Prote AG.

- Edition 12.2017
– Unbolt clamp -arrow- for high-pressure line.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Counter hold union -A- and unscrew union nut -arrow-.
– Unscrew union nut -arrow- on fuel rail using socket AF 17 mm

- T10456- , and remove high-pressure line.
Note
♦ The fuel system must not be ounder
lksw pressure.
age es n
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♦ Collect escaping fuel with
rised a clean cloth. ran
tee
ho
ut or
♦ Seal open connections
ss
a with clean caps. Ensure that no dirt ac
gets into the fuel system.
ce
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nl
pt
du
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itte
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erm
ab
ility
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– Loosen securing nut -3- slightly, and unscrew bolt -1- com‐
wit
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pletely.
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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at
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ion
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or
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

- Edition 12.2017
– Pull off electrical connector -1- from Hall sender - G40- .
– Pull connector -1- off intake manifold flap potentiometer -

G336- .
– Unscrew nuts -A- from intake manifold, and unscrew bolts

-arrows- using socket Torx T30 - T10347- .
AG. Volkswagen AG d
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– Slightly pull off intake manifold from cylinder head and un‐
hole
screw bolts -arrows-for bracket -A-.

spec
es, in part or in w
– Take intake manifold off cylinder head.

t to the co
Note
rrectness of i
l purpos
Seal intake ports with a clean cloth.

nf
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Installing
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If the union on the high-pressure pump has been detached, renew

t.
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union. Cop py
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Prote AG.

- Edition 12.2017
– Screw on nuts -A- hand-tight.

– Using socket Torx T30 - T10347- , tighten bolts -arrows- even‐
ly from inside to outside.
Specified torques
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”,
page 298
3.3 Removing and installing throttle valve

module - GX3-
Throttle valve module - GX3- consists of
♦ Throttle valve drive for electronic power control - G186-
♦ Throttle valve drive angle sender 1 for electronic power control
- G187-
♦ Throttle valve drive angle sender 2 for electronic power control
- G188-
Removing
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d ran
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spec

es, in part or in w
-1-.
t to the co
rrectness of i
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orm
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olkswagen AG
g en AG. V
Golf 2013 ➤ , Golf 2015 olk➤
swa, Golf 2017 ➤ , GolfdVariant
oes
not 2014 ➤ , Golf V ...
yV gu
ed b chain drive, generation III) Volkswagen
ara
nte
R GmbH
ris
utho - Edition
eo
r
12.2017
a ac
ss
ce
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nl
pt
du
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itte
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erm
ab
– Remove noise insulation -1- ⇒ General body repairs, exterior;
ility
ot p
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sulation .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release hose clips -1 and 2-, and remove air intake hose.
nform
mercia
at
om
ion
c
in t
or
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ate
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for
en
ng
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– Release hose clip -2- on air hose and pull air hose off throttle
valve module - GX3- .
– Remove air intake hose downwards.

- Edition 12.2017
– Detach electrical connector -1- from throttle valve module .

– Unscrew bolts -arrows- on throttle valve module from under‐
neath and detach throttle valve module .
Installing
– Clean sealing surface for O-ring.
– Renew seal.
Specified torques
– After throttle valve module is renewed, it must be readapted
to control unit - J623- ⇒ Vehicle diagnostic tester.
3.4 Cleaning throttle valve module
Note
♦ If a new engine control unit - J623- is installed, the throttle

valve module must be adapted.
♦ Contamination and coking in end stop can result in incorrect
adaptation values.
♦ When cleaning the throttle valve housing, take care not to
scratch it.

♦ Acetone (commercially available)
♦ Brush
– Remove throttle valve module ⇒ page 294 .
– Open throttle valve by hand and lock it in open position withna
AG. Volkswagen AG d
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wedge (plastic or wood) -arrow-. yV
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ed ran
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WARNING th or
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Acetone is highly inflammable.

un
pt
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♦ Observe accident prevention regulations and safety notes

erm
ab
when handling highly inflammable fluids.

ility
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♦ Do not use compressed air to clean throttle valve.

h re
ole,
spec
♦ Wear eye protection and protective clothing to avoid injury

and skin contact.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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296
co Vo
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Rep. gr.24 - Mixture preparation - injection cted agen
Prote AG.
- Edition 12.2017
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe the inside of the throttle valve housing with a lint-free
cloth.
– Allow acetone to dry off completely.
– Install throttle valve module ⇒ page 294 .
– Delete learnt values, and adapt engine control unit - J623- to
throttle valve module ⇒ Vehicle diagnostic tester.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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cted agen
Prote AG.

- Edition 12.2017
4 Injectors
⇒ “4.1 Assembly overview - fuel rail with injectors”, page 298
⇒ “4.2 Removing and installing fuel rail”, page 300
⇒ “4.3 Removing and installing injectors”, page 301
⇒ “4.4 Renewing seals on injectors”, page 304
⇒ “4.5 Cleaning injectors”, page 307
4.1 Assembly overview - fuel rail with injec‐

tors
⇒ “4.1.1 Assembly overview - fuel rail with injectors, direct injec‐
tion”, page 298
⇒ “4.1.2 Assembly overview - fuel rail with injectors, indirect in‐
jection”, page 299
4.1.1 Assembly overview - fuel rail with injectors, direct injection
1 - Bolt
❑ Qty. 2
AG. Volkswagen AG d
❑ 9 Nm agen oes
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by ara
2 - Fuel rail for injectors (com‐ rised
nte
bustion chamber) aut
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❑ Removing and installing s
ce
le
⇒ page 300
un
pt
an
d
itte
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3 - Fuel pressure sender -
rm
ab
G247-
pe
ility
ot
wit
❑ Moisten taper and
, is n
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thread with clean engine
hole
oil
spec
es, in part or in w
t to the co
⇒ page 310
❑ 27 Nm
rrectness of i
4 - Support ring
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5 - O-ring
nform
ercia

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com
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6 - Spacer ring
on in
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7 - Injection valve
r
rp
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fo
❑ Ensure correct installa‐

en
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tion position
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⇒ page 301
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cted agen
Prote AG.
8 - Sealing disc
9 - Combustion chamber seal
❑ Renew after removing
injector ⇒ page 301
10 - Union
❑ For high-pressure line on fuel rail

- Edition 12.2017
❑ Lubricate thread with clean engine oil
❑ Counterhold on fuel rail when tightening
❑ 40 Nm
11 - Bolt
❑ 5 Nm
12 - High-pressure line
❑ Moisten ball with clean engine oil
❑ 20 Nm
4.1.2 Assembly overview - fuel rail with injectors, indirect injection
1 - Retaining clip
❑ For fuel pressure send‐
er for low pressure -
G410-
2 - O-ring
3 - Adapter
❑ Must be screwed onto
fuel pressure sender for
low pressure - G410-
-item 4-
❑ 15 Nm
4 - Fuel pressure sender for
low-pressure - G410-
❑ Must be screwed onto
adapter -item 3-
❑ Removing and installing wage
es n
⇒ page 312 yV
olks ot g
ua
d b
❑ 15 Nm o
ir se
ran
te
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ut ra
5 - Fuel rail for injectors
ss
a (intake c
manifold)
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d
6 - Bolt
itte
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rm
ab
❑ Qty. 2
pe
ility
ot
❑ 9 Nm
wit
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7 - Fuel supply line

hole
spec
❑ To fuel rail for injectors

es, in part or in w
t to the co
(intake manifold)
❑ Install free of tension.
rrectness of i
8 - Retaining clip
l purpos
9 - O-ring
nform
ercia
10 - Injection valve
m
❑ Ensure correct installation position

com
tion in

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11 - O-ring
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4. Injectors 299
- Edition 12.2017
4.2 Removing and installing fuel rail
Note
In this section, the work procedure for direct injection engines is

described.
Removing
– Remove intake manifold ⇒ page 289 .
– Separate electrical connector -1- on fuel pressure sender -
G247- .
– Move clear wiring duct -2- at fuel rail, and pull fuel rail off in‐
jectors.
Note
If injectors remain inserted in the fuel rail, disconnect the relevant

connector.
Installing
– Install intake manifold ⇒ page 289 .
AG. Volkswagen AG d
Specified torques agen oes
olksw not
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ara
♦ ⇒ “4.1.1 Assembly overview - fuel
ris rail with injectors, direct in‐
ed
nte
jection”, page 298 ut
ho eo
ra
s a c
s
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un
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an
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rm
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pe
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hole
spec
es, in part or in w
t to the co
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Cop py
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rig ht
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- Edition 12.2017
4.3 Removing and installing injectors

⇒ “4.3.1 Removing and installing injectors, direct injection”, page
301
⇒ “4.3.2 Removing and installing injectors, indirect injection”,
page 303
4.3.1 Removing and installing injectors, direct

injection
Special tools and work‐
shop equipment re‐
quired
♦ Tool set - T10133-
AG. Volkswagen AG d
agen oes
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Assembly overview - in‐

wit
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jector
h re
hole
spec
1 - Renew intermediate
es, in part or in w
ring.
t to the co
2 - Renew retainer.
rrectness of i
3 - Renew combustion
chamber ring seal (Tef‐
l purpos
lon seal). On installation,

do not grease ring or
treat with any other lubri‐
nform
ercia
cant.
m
at
om
4 - Injection valve
ion
c
in t
or
5 - Renew spacer ring.

his
ate
do
riv
6 - Renew O-ring (apply

p
cum
or
thin coating of clean en‐

f
en
ng
t.
gine oil prior to installa‐
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7 - Renew support ring.
co Vo
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cted
Via this support ring, fuel
agen
Prote AG.
rail exerts force which
secures injector in cylin‐
der head.
Removing
Note
Injectors must only be re‐

moved when the engine
is cold.
– Remove intake mani‐

fold ⇒ page 289 .
4. Injectors 301
- Edition 12.2017
– Removing fuel rail

⇒ page 300 .
Note
Remove injectors if they

remain in fuel rail.
Carefully pull out injec‐

tors from fuel rail.
Note
Remove injectors if they

remain in cylinder head.
– Cover open intake

ports with a clean
cloth.
– Detach electrical con‐
nector from injector
that is to be removed. AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Fit impact sleeve -T10133/18- ised bover injector. ara
nte
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aut ra
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un
pt
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spec
es, in part or in w
t to the co
rrectness of i
– Carefully loosen injector with several light blows onto impact

sleeve.
l purpos
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mercia
a
com
tion in
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Prote AG.

- Edition 12.2017
– Insert puller -T10133/2A- into groove in injector.

– Fit puller T10133/16A .
– Pull out injector by turning bolt with torque wrench -1-.
– If torque limit of »5 Nm« has been reached and the injector still
cannot be pulled out, remove puller, and try to loosen injector
again using impact sleeve.
Note
♦ If the torque limit is exceeded, the injector may become dam‐

aged.
♦ The combustion chamber ring seal must always be renewed
AG. Volkswagen
prior to reinstallation of the
lkswinjector ⇒ page 304 . es no
agen AG do
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– Renew combustiontho ring seal and install injector tee o
⇒ page 304 .s au ra
c
s
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nl
pt
du
an
4.3.2 Removing and installing injectors, indi‐
itte
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erm
ab
rect injection
ility
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Removing
h re
hole
spec
es, in part or in w
t to the co
– Release fasteners -arrows- and detach wiring duct -1- from
bracket.
rrectness of i
Note
l purpos
Disregard -item 2-.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Unscrew bolt -1- for upper coolant pipe -arrow-.
Co
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by c lksw
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Prote AG.
4. Injectors 303
- Edition 12.2017
2 - For fuel pressure sender for low pressure - G410-
3 - For intake manifold sender - GX9- .
4 - Intermediate connector for injectors (intake manifold)
– Move clear wiring harness -1- at engine lifting eye.
– Unscrew bolts -arrows- at fuel rail.
– Unscrew bolt -5- for retainer of connector.
– Carefully pull out fuel rail with injectors upwards.
– Separate connector -4-.

– Pull off retaining clip -2-, and pull injector -3- off fuel rail -1-.
AG. Volkswagen AG d
agen oes
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ara
ed
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Installing
ce
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un
pt
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itte
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ab
– Renew O-rings -1, 4- for injector -2-.
ility
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wit
is n
– Before installing O-rings, lightly moisten them with clean en‐
h re
ole,
gine oil.
spec
– Secure injector in fuel rail using retaining clip -3-.
t to the co
– Connect connectors.
– Push fuel rail with injectors by hand as far as stop into hole in
rrectne
intake manifold (which must be free of oil and grease).
Specified torques
ss o
cial p
f
♦ ⇒ page 299
inform
mer
atio
4.4 Renewing seals on injectors
om
n
c
i
or
n thi
te
sd
iva
Note
pr
cum
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fo
en
ng
t.
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The combustion chamber ring seal must always be renewed prior
Co
op py
to reinstalling the injector.
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ht ht
rig by
copy Vo
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Prote AG.

AG. Volkchain
swagedrive,
n AG d generation III) Volkswagen R GmbH
agen oes
Vo lksw not
g
- Edition 12.2017
y ua
db ran
rise tee
– Carefully remove combustion ut
ho chamber ring seal -3- using a or
suitable tool (e.g. cut ring
ss aopen using razor blade, or prise ring ac
open with small screwdriver and then pull it off forwards). It is
ce
e
nl
pt
essential to ensure that the groove and continuous ridge in
du
an
itte
groove surface are not damaged.
y li
erm
ab
ility
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wit
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Note
h re
hole
spec
Injector must be renewed if groove is damaged.
es, in part or in w
t to the co
– Before new combustion chamber ring seal is fitted, remove
any combustion residues from groove for combustion cham‐
rrectness of i
ber ring seal and from injector shaft using a clean cloth.
l purpos
– Fit assembly cone -T10133/5- with new combustion chamber

seal -1- onto injector -2-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Prote AG.
– Slide combustion chamber ring seal with assembly sleeve -

T10133/6- onto assembly cone -T10133/5- as far as it will go.
– Turn over assembly sleeve - T10133/6- , and push combustion

chamber ring seal onto end of assembly cone - T10133/5- .
– Remove assembly cone - T10133/5- , and push combustion
chamber ring seal into groove for combustion chamber ring
seal using assembly sleeve - T10133/6- .
4. Injectors 305
- Edition 12.2017
– Push calibration sleeve -T10133/7- onto injector to stop and

simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again, turning in opposite
direction.
– Push calibration sleeve -T10133/8- onto injector to stop and

simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again, turning in opposite
direction.
– Renew O-ring on injector. Before installing new O-ring, lightly
moisten it with clean engine oil.
– Before installing injectors, thoroughly clean injector holes in

cylinder head with nylon brush - T10133/4- provided.
Note
lkswage es n
Vo ot g
♦ The combustion chamber seal on the injector must not be oiled ed
by ua
ran
or greased. thoris tee
or
au ac
♦ There must be no cleaning fluid or oil in the bores in the
ss cyl‐
ce
inder head when installing the injector.
le
un
pt
an
d
itte
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erm
– Push injector by hand as far as it will go into the hole of the
ab
ility
cylinder head (which must be free of oil and grease). Ensure
ot p
wit
injectors are positioned correctly in cylinder head.
is n
h re
ole,
– Lug -1- and hole -arrow- in cylinder head must face each other. spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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Cop py
t. rig
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co lksw
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Prote AG.

- Edition 12.2017
Note
♦ It should be possible to insert the injector easily. If necessary,

wait until the combustion chamber ring seal has contracted
sufficiently.
♦ Ensure injectors are correctly seated and positioned in cylin‐
der head.
♦ If it is not possible to insert the injector by hand, use the puller
- T10133/2A- -2- with a hammer - T10133/3- to insert the in‐
jector.
– Coat O-rings of injectors with clean engine oil to facilitate in‐

sertion into fuel rail.
– Installing fuel rail ⇒ page 300 .
– Install intake manifold ⇒ page 289 .
4.5 Cleaning injectors

lkswage es n
o ot g
byV ua
d ran
Note o
ir se tee
th or
au ac
ss
In this section, the work procedure for injectors (combustion
ce
e
chamber) is described.
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
♦ Ultrasonic cleaning device - VAS 6418-
, is n
h re
hole
♦ Mounting plate for injection modules - VAS 6418/1-
spec
es, in part or in w
♦ Cleaning fluid - VAS 6418/2-
t to the co
Cleaning
rrectness of i
– Close drain tap -arrow- of ultrasonic cleaning unit - VAS 6418-
at right-hand side of housing.
l purpos
– Fill ultrasonic cleaning unit with 2120 ml of water which was

allowed to stand for a while and with cleaning fluid - VAS
nform
ercia
6418/2- .
m
at
Mixing ratio for cleaning fluid

om
ion
c
in t
r
• 2100 ml of water which was allowed to stand for a while and

o
his
te
20 ml of cleaning fluid - VAS 6418/2- .

a
do
priv
cum
or
– Remove injectors ⇒ page 301 .

f
en
ng
t.
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Cop py
t. rig
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co lksw
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Prote AG.
4. Injectors 307
G. V V ...agen AG d olksw
Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 wa➤
gen, A
Golf oes
olks not
d by V drive, generation III) Volkswagen gu R GmbH
ara
- Edition 12.2017 horis
e nte
e t or
au ac
ss
– Fit mounting plate for injection modules - VAS 6418/1- onto
ce
e
nl
cleaning unit.
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ Before starting ultrasonic cleaning unit - VAS 6418- , it is es‐
hole
spec
sential that the safety information described in the operating
es, in part or in w
manual is observed.
t to the co
♦ The ideal fluid level is reached when the cleaning agent is ap‐
prox. 1 to 4 mm above the base of the support plate. The
rrectness of i
ultrasonic cleaner - VAS 6418- could become damaged if the
fluid level is too low.
l purpos
– Insert injectors into guides of mounting plate for injection mod‐
nf
ercia
ules - VAS 6418/1- as far as stop.
orm
m
atio
m
– Switch on cleaning unit by pressing on/off button -C-.

o
n in
or c
thi
e
– Use rotary knob -A- to set cleaning time to 30 minutes.

t
sd
iva
o
r
rp
cu
– Set rotary knob -B- to a temperature of 50°C.
o
m
f
en
ng
t.
yi
– Press button ► -D- to start the cleaning process.
Co
Cop py
t. rig
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by
Note cted agen
Prote AG.
♦ Temperature-controlled cleaning is now activated. During the

warm-up period, ultrasonic waves are activated to mix the
cleaning fluid. Once the preselected temperature is reached,
the ultrasonic waves are switched to continuous operation.
♦ The cleaning time must be at least 30 minutes and cleaning
only starts at a temperature of at least 50°C.
– Each time after cleaning injectors (combustion chamber), re‐

new combustion chamber seal (Teflon ring seal)
⇒ page 304 .
– Install injectors (combustion chamber) ⇒ page 301 .

- Edition 12.2017
5 Senders and sensors

⇒ “5.1 Assembly overview - actuator for structure-borne sound
and control unit for structure-borne sound”, page 309
⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page
310
⇒ “5.3 Removing and installing fuel pressure sender for low-pres‐
sure G410 ”, page 312
⇒ “5.4 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 314
⇒ “5.5 Removing and installing actuator for structure-borne sound
R214 ”, page 314
5.1 Assembly overview - actuator for structure-borne sound and control unit for
structure-borne sound
1 - Actuator for structure-borne

sound - R214-
❑ Fitting location: in ple‐
num chamber
⇒ page 314
2 - Bracket
❑ For actuator for struc‐
AG. Volkswagen AG d
ture-borne sound - ksw
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not
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R214- and control unit by
Vo gu
ara
for structure-borne rised
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sound - J869- . aut
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❑ Can only be renewed s
ce
e
with windscreen re‐

nl
pt
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3 - Control unit for structure-
ility
ot p
borne sound - J869-
wit
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❑ Fitting location: in ple‐
hole
num chamber
spec
es, in part or in w
❑ Remove plenum cham‐
t to the co
ber for removing ⇒ Gen‐
eral body repairs, exte‐
rior; Rep. gr. 50 ;
rrectness of i
Plenum chamber bulk‐
head; Removing and in‐
l purpos
stalling plenum cham‐

ber cover .
nf
ercia
❑ Secured with a bolt or 2

rm
m
nuts (depending on ver‐

atio
m
sion)
o
n in
or c
thi
te
sd
iva
❑ for control unit for struc‐

r
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o
ture-borne sound -
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J869-
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5 - Nut
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❑ for actuator for structure-borne sound - R214-
by c lksw
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Prote AG.
❑ 7 Nm
6 - Nut
❑ 9 Nm
5. Senders and sensors 309

- Edition 12.2017
7 - Bolt/nut
❑ for control unit for structure-borne sound - J869-
❑ 3 Nm
8 - Bolt
❑ 9 Nm
❑ for actuator for structure-borne sound - R214-
5.2 Removing and installing fuel pressure

sender - G247-
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
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spec
♦ Socket 27 mm - T40218- or commercially available 27 mm

t to the co
hexagon socket insert
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
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t.
Use ⇒ Vehicle diagnostic tester for checking fuel pressure sender op
yi Co
- G247- .
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If fuel pressure sender - G247- fails, fuel pressure regulating valve co Vo
by lksw
- N276- is switched off, electric fuel pump is fully actuated, and
cted agen
Prote AG.
engine is operated with available fuel pressure. This reduces the
engine torque drastically.
Removing

- Edition 12.2017
– Unscrew coolant pipe bolts -arrows- from intake manifold.


sulation .

G. Volkswage
– Loosen hose clip -2- on wair
agehose
nA and pullnair
AGhose
does downwards
olks - GX3- .
off throttle valve module
V
not
gu
by a
ed ran
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ss
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove intake manifold support. To do this, unscrew securing

l purpos
nut -2- and bolt -3-.

– Remove rubber bush -1- for intake manifold support.
nf
ercia
orm
m
atio
WARNING
om
n in
or c
thi
e
The fuel system is under high pressure. Always release pres‐

t
sd
iva
sure in the high-pressure system prior to opening the fuel

o
r
rp
cu
system. For procedure, please see ⇒ page 284 .

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- Edition 12.2017
– Release connector for fuel pressure sender - G247- -1- using

assembly tool - T10118- .
– Pull off connector -arrow- from alternator, otherwise the bit can
be caught on the connector!
– Unscrew fuel pressure sender - G247- using bit 27 mm -
T40218- .
Installing
Specified torques
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 298
5.3 Removing and installing fuel pressure

sender for low-pressure - G410- wage
es n
olks ot g
Removing byV ua
d ran
ir se tee
o
– Remove engine cover panel ⇒ page 38 . auth or
ac
ss
– Pull connector -2- off fuel pressure sender for low-pressure -
ce
le
un
pt
G410- -1-.
an
d
itte
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rm
ab
pe
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
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tion in
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s
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en
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by
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Prote AG.

lkswage es n
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byV Golf 2013 ➤ , Golf 2015 ➤ ua, Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
d ran
ir se
tho engine (2.0 l, 4 V, turbocharger, chain tee
odrive, generation III) Volkswagen R GmbH
u ra
ss
a c - Edition 12.2017
ce
e
nl
pt
du
– Pull out retaining clip -2-.
an
itte
y li
erm
ab
– Pull fuel pressure sender for low-pressure - G410- -1- out of
ility
ot p
fuel rail.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
yi
– Unscrew fuel pressure sender for low-pressure - G410- -1-
Co
op py
from adapter -2-.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing
– Renew O-ring -arrow-.
– Screw fuel pressure sender for low-pressure - G410- -1- into
adapter -2-.

- Edition 12.2017
– Carefully push fuel pressure sender for low-pressure - G410-

-1- into fuel rail as far as stop.
– Slide retaining clip -2- into groove to secure fuel pressure
sender for low-pressure - G410- .
– Connect electrical connector.
AG. Volkswagen AG d
Specified torques agen oes
olksw not
y V gu
b ara
♦ ⇒ “4.1 Assembly overview - fuel rail with injectors”,
rise
d
page 298 nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5.4 Removing and installing intake air tem‐
rrectness of i
perature sender - G42- / intake manifold
l purpos
pressure sender - G71-
nform
ercia
Removing
m
at
om
ion
c
in t
r

o
his
ate
do
riv

p
cum
for
– Release fasteners -arrows-, and pull intake air temperature
en
ng
t.
yi Co
sender - G42- / intake manifold pressure sender - G71- off Cop py
intake manifold.
t. rig
gh ht
pyri by
Vo
o
Installing
c by lksw
cted agen
Prote AG.
Specified torques
5.5 Removing and installing actuator for

structure-borne sound - R214-
Removing
Note
♦ The bracket for the actuator for structure-borne sound - R214-

remains installed.
♦ The bracket can only be renewed with the windscreen re‐
moved.
– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .

- Edition 12.2017

– Unscrew nut -1-.
– Remove actuator for structure-borne sound - R214- -3-.
Installing
Specified torques
♦ ⇒ “5.1 Assembly overview - actuator for structure-borne sound
and control unit for structure-borne sound”, page 309
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
315
cted agen
Prote AG.
5. Senders and sensors
- Edition 12.2017
6 High-pressure pump
⇒ “6.1 Assembly overview - high-pressure pump”, page 316
⇒ “6.2 Removing and installing high-pressure pump”, page 317
6.1 Assembly overview - high-pressure

pump lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV ua
edb ran
ris
WARNING ho
tee
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
1 - Bolt
spec
es, in part or in w
t to the co
❑ Tighten evenly.
❑ 20 Nm
rrectness of i
2 - Fuel pressure regulating
l purpos
valve - N276-
nform
ercia
❑ For fuel pressure regu‐

m
lating valve - N276- .
at
om
ion
c
4 - High-pressure pump
in t
or
his
te
❑ Fuel tank contains elec‐

a
do
riv
tric fuel pump which

p
cum
or
pumps fuel to mechani‐

f
en
ng
t.
cal high-pressure pump.
yi Co
Cop py
t.
❑ When installing the
rig
gh ht
yri by
high-pressure pump, it cop Vo
by lksw
is essential to ensure cted agen
Prote AG.
that no dirt enters the
fuel system.
❑ The fuel system must
not be under pressure;
procedure for reducing
fuel pressure
⇒ page 284 .
❑ Install fuel lines free of
stress.
❑ Check O-ring and renew
if damaged.
⇒ page 317
5 - O-ring
6 - Roller tappet
❑ Installation position: roller faces towards camshaft
❑ Can remain inserted in vacuum pump after removal of high-pressure pump
7 - Connecting piece for fuel line
❑ 20 Nm

- Edition 12.2017
9 - Fuel line
❑ To fuel rail for injectors (intake manifold).
10 - High-pressure line
❑ To fuel rail for injectors (combustion chamber).
❑ Moisten ball of high-pressure line with engine oil
❑ High-pressure line must be free of tension when installed
❑ Ensure cleanliness!
❑ 20 Nm olkswage es n
o V t gu
by ara
11 - Connecting piece for high-pressureris
ed line nte
ho eo
❑ If the connecting piece is released,
au
t it must be renewed ra
c
ss
❑ 30 Nm
ce
e
nl
pt
du
an
12 - Fuel supply line
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
6.2 Removing and installing high-pressure
pump
rrectness of i
l purpos
♦ Socket, 17 mm - T10456-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ high-pressure pump may only be removed when the engine is

cold.
♦ When installing the high-pressure pump, it is essential to en‐
sure that no dirt enters the fuel system.
♦ Collect escaping fuel with a cleaning cloth.
♦ Check O-ring of high-pressure pump and renew it if damaged.
♦ If union for high-pressure line ⇒ Item 11 (page 317) is re‐
leased, it must be renewed.
♦ Moisten high-pressure line with engine oil and always make
sure it is free of stress when installed.
Removing
6. High-pressure pump 317

- Edition 12.2017
WARNING


olkswagen AG
– Free electrical wiring harnesses -1- and -2- fromswfittings
agen and
AG. V does
lay them to one side. by
Volk not
gu
ara
ed nte
– Loosen screw-type clip -3-. ris
tho eo
au ra
c
– Unscrew bolts -arrows-. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Loosen hose clip -arrow-, and remove left charge air hose
-1- downwards, together with air pipe.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
.
t rig
gh ht
yri by
bracket and press forwards. cop Vo
by lksw
cted agen
Prote
– Unscrew bolts -1, 2 and 3-.
AG.
– Unbolt clamp -arrow-.

- Edition 12.2017
– Loosen union nut -arrow- on fuel rail -arrow- using socket AF

17 mm - T10456- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
– Counterhold on hexagon -A-, and loosen union nut -arrow-.
an
d
itte
y li
Remove high-pressure line.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Pull electrical connector -1- from fuel pressure regulating valve
form
mer
- N276- .
atio
om
– Remove fuel hoses -2- and -3-.
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
– Carefully pull out high-pressure pump. The roller plunger may

r
fo
en
ng
possibly remain inserted in vacuum pump.

t.
yi Co
Cop py
Installing ht. rig
rig ht
py by
o Vo
Install in reverse order of removal, observing the following: by c lksw
cted agen
Prote AG.
– Renew high-pressure pump O-ring.
– Before inserting roller tappet, check it for damage, and renew
it if necessary.
– Insert roller plunger into vacuum pump as shown.
Note
♦ Roller tappet must be at bottom dead centre to enable high-

pressure pump to be installed.
♦ If union for high-pressure line ⇒ Item 11 (page 317) is re‐
leased, it must be renewed.
– Turn crankshaft until roller tappet is at bottom dead centre.

– Insert high-pressure pump into vacuum pump.
6. High-pressure pump 319

- Edition 12.2017
– Tighten bolts -arrows- alternately and diagonally by hand.

– Tighten bolts in diagonal sequence to specified torque.
– Connect fuel hoses -2- and -3-, and secure them with spring-
type clips.
– Connect connector -1- to fuel pressure regulating valve -
N276- .
– Moisten balls of high-pressure line with engine oil, and install
high-pressure line. Tighten union nuts by hand, and align high-
pressure line free of stress.
– Tighten union nut on fuel rail -arrow- using socket AF 17 mm

- T10456- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
– Counterhold on hexagon -A-, and tighten union nut -arrow-. ab

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Install clamp -arrow-.

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
yi
Upon completion of any repair work, check fuel system for leaks.
Co
Cop py
t. rig
gh ht
yri by
Specified torques
op Vo
by c lksw
cted agen
Prote AG.

- Edition 12.2017
7 Lambda probe
⇒ “7.1 Assembly overview - Lambda probe”, page 321
⇒ “7.2 Removing and installing Lambda probe”, page 322
AG. Volkswagen AG d
agen
7.1 AssemblyVol overview - Lambda probe
es n o
ksw ot g
by ua
ed ran
oris tee
th or
au ac
Note ss
ce
e
nl
pt
du
♦ New lambda probes are coated with an assembly paste. This paste must not get into the slots on the Lambda
an
itte
y li
probe body.
erm
ab
ility
ot p
♦ In the case of a used Lambda probe, grease only the thread with high-temperature paste. This paste must
wit
, is n
not get into the slots on the Lambda probe body. High-temperature paste ⇒ Electronic Parts Catalogue .
h re
hole
spec
♦ During installation, the electrical connecting cable of the Lambda probe must be secured at the same points.
es, in part or in w
The wire must be prevented from touching the exhaust pipe.
t to the co
rrectness of i
1 - Lambda probe 1 after cata‐
lytic converter - GX7-
l purpos

⇒ page 323
nf
ercia
❑ 55 Nm
orm
m
atio
2 - Lambda probe 1 before cat‐
om
n in
alytic converter - GX10-
or c
thi
e

t
sd
iva
⇒ page 322
o
r
rp
cu
o
❑ 55 Nm
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Lambda probe 321

- Edition 12.2017
7.2 Removing and installing Lambda probe

⇒ “7.2.1 Removing and installing Lambda probe 1 before catalytic
converter GX10 ”, page 322
⇒ “7.2.2 Removing and installing Lambda probe 1 after catalytic
converter GX7 ”, page 323
7.2.1 Removing and installing Lambda agen

probe
AG. Volkswagen AG d
oes
1 before catalytic converter
db
y V - GX10-
olksw not
gu
ar
e an
ris tee
Special tools and workshop equipment urequired
tho or
sa ac
♦ Lambda probe open ring spanner sset - 3337-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
Lambda probe 1 before catalytic converter - GX10- consists of
f inform
mer
♦ Lambda probe - G39-
atio
m
♦ Lambda probe heater - Z19-

o
n
c
i
or
n thi
Removing
te
sd
iva
o
pr
c
– Separate connector -2- of lambda probe 1 before catalytic
um
r
fo
converter - GX10- .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

- Edition 12.2017
– Unscrew Lambda probe 1 before catalytic converter - GX10-

-1- using tool from Lambda probe open ring spanner set -
3337- .
AG. Volkswagen AG d
Installing agen oes
olksw not
byV gu
ara
Install in reverse
rised
order of removal, observing the following:
nte
ho eo
aut ra
s s c
ce
Note
le
un
pt
an
d
itte
y li
♦ New lambda probes are coated with an assembly paste. This
erm
ab
paste must not get into the slots on the Lambda probe body.
ility
ot p
wit
is n
♦ In the case of a used Lambda probe, grease only the thread
h re
ole,
with high-temperature paste. This paste must not get into the
spec
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue (ETKA) .
t to the co
♦ During installation, the electrical connecting cable of the
Lambda probe must be secured at the same points. The wire
rrectne
must be prevented from touching the exhaust pipe.
ss
Specified torques
o
cial p
f in
form
mer
atio
m
7.2.2 Removing and installing Lambda probe

o
n
c
i
or
n thi
1 after catalytic converter - GX7-

te
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi
♦ Lambda probe open ring spanner set - 3337-
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Lambda probe 1 after catalytic converter - GX7- consists of

♦ Lambda probe after catalytic converter - G130-
♦ Lambda probe 1 heater after catalytic converter - Z29-
Removing
– Separate connector -1- of lambda probe 1 after catalytic con‐
verter - GX7- .
7. Lambda probe 323

- Edition 12.2017 en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
– Unscrew Lambda probe -1-, using tool from Lambda probe ed
b ara
nte
open ring spanner set - 3337- . oris eo
th
au ra
c
Installing ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
♦ New lambda probes are coated with an assembly paste. This
spec
paste must not get into the slots on the Lambda probe body.
t to the co
♦ In the case of a used Lambda probe, grease only the thread
with high-temperature paste. This paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
rrectne
Electronic parts catalogue (ETKA) .
s
♦ During installation, the electrical connecting cable of the
s o
Lambda probe must be secured at the same points. The wire
cial p
f in
must be prevented from touching the exhaust pipe.
form
mer
atio
m
Specified torques
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
8 Engine (motor) control unit

⇒ “8.1 Removing and installing engine (motor) control unit J623
”, page 325
8.1 Removing and installing engine (motor)

control unit - J623-
⇒ “8.1.1 Removing and installing engine control unit J623 without
protective housing”, page 325
AG . Volkswage
⇒ “8.1.2 Removing and installing
ksw
agenengine (motor)Acontrol
n Gd
oes unit J623
not
l
with protective housing”,
by page 325
Vo gu
a
ed ran
ris te
8.1.1 Removing and installing engine controle or a
au
tho
unit - J623- without protective housing

ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Removing
h re
hole
– Before removing the engine control unit, the adaption values
spec
es, in part or in w
for the chain length must be read out of the engine control unit.
t to the co
– Activate Renew engine control unit function in Guided
Functions mode ⇒ Vehicle diagnostic tester.
rrectness of i
– Switch off ignition and remove key from ignition lock.
l purpos
Caution nform
ercia
If the engine (motor) control unit comes into contact with the
m
at
om
positive battery terminal, permanent damage to the engine

ion
c
(motor) control unit will be the consequence. For this reason,

in t
or
the battery always needs to be disconnected prior to removing

his
ate
do
riv
the engine control unit from its bracket ⇒ Electrical system;

p
cum
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

for
en
ng
t.
yi Co
Cop py
t. rig
gh
– Release and disconnect connectors -2 and 3- for engine con‐
ht
pyri by
Vo
trol unit - J623- .
o
by c lksw
cted agen
Prote AG.
– Release fastener -arrow A-, and remove engine control unit -
J623- -1- -arrow B-.
Installing
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
8.1.2 Removing and installing engine (motor)

control unit - J623- with protective hous‐
ing
8. Engine (motor) control unit 325

- Edition 12.2017
♦ Hot air blower - VAS 1978/14A- with nozzle attachment from

wiring harness repair set - VAS 1978 B-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Small grinder (commercially available)
h re
hole
spec
es, in part or in w
t to the co
Removing
– Before removing the engine control unit, the adaption values
rrectness of i
for the chain length must be read out of the engine control unit.
l purpos
nf
ercia
– Switch off ignition and remove key from ignition lock.

orm
m
atio
om
Caution
n in
or c
thi
te
sd
a
If the engine (motor) control unit comes into contact with the
iv
o
r
rp
cu
positive battery terminal, permanent damage to the engine

o
m
f
(motor) control unit will be the consequence. For this reason,

en
ng
t.
yi Co
the battery always needs to be disconnected prior to removing Cop py
the engine control unit from its bracket ⇒ Electrical system;
t. rig
gh ht
yri
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
p by
o Vo
by c lksw
cted agen
Prote AG.
To remove protective housing -1-, unscrew shear bolts -arrows-

as follows:
– Make groove (for a screwdriver) in head of shear bolt -1- using

a small grinder -2-.

- Edition 12.2017
Note
The threads of the shear bolts are secured with locking fluid. To
unscrew these bolts, the threads must therefore be heated with
the hot air blower.
– Set hot air blower proceeding as shown in illustration, i.e. turn

potentiometer for temperature adjustment -2- to maximum
heating output, and set two-stage switch for air flow rate -3- to
position 3.
WARNING
Risk of burns from hot air blower

♦ Parts of the protective housing will become very hot as a
result of heating the threads. Also ensure that only the
thread is heated and none of the surrounding compo‐
nents, if at all possible. Cover surrounding components, if
necessary.
– Heat head of shear bolt -1- for approx. 20 to 30 seconds.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew shear bolt -1- with screwdriver -2-.
hole
spec
es, in part or in w
– Remove protective housing from engine (motor) control unit -
t to the co
J623- .
– Release and disconnect connectors -2 and 3- for engine con‐ rrectness of i
trol unit - J623- .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8. Engine (motor) control unit 327

- Edition 12.2017
– Release fastener -arrow A-, and remove engine control unit -

J623- -1- -arrow B-.
Installing
– It is essential that the engine (motor) control unit - J623- be
provided with the protective housing again.
– Clean threaded holes for shear-head bolts from locking fluid
residue. A thread chaser is suitable for cleaning.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 329
⇒ “1.2 Removing and installing silencer”, page 334
⇒ “1.3 Separating exhaust pipes from silencers”, page 334
wage es n
⇒ “1.4 Aligning exhaust system free of stress”, page 335 y Volks ot g
ua
b
ed ran
⇒ “1.5 Align end exhaust pipes”, page 336 ho
ris tee
t or
au ac
⇒ “1.6 Check exhaust system for leaks”, page 336
ss
ce
le
un
pt
⇒ “1.7 Installation position of clamp”, page 337
an
d
itte
y li
erm
1.1 Assembly overview - silencers
ab
ility
ot p
wit
⇒ “1.1.1 Assembly overview - silencers”, page 329
is n
h re
ole,
⇒ “1.1.2 Assembly overview - silencers, titanium”, page 331
spec
⇒ “1.1.3 Assembly overview - silencers, estate, 4MOTION”, page
t to the co
332
1.1.1 Assembly overview - silencers
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Exhaust pipes and silencers 329

- Edition 12.2017
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Retaining ring
4 - Retaining ring
5 - Rear clamp
⇒ page 337
❑ Aligning exhaust sys‐
tem free of tension
⇒ page 335 .
. Volkswagen AG
❑ Tighten threaded kcon‐ gen AG does
l swa not
nections evenly.
by
Vo gu
a d ran
ise
6 - Nut ut
ho
r tee
or
a ac
❑ 20 Nm
ss
ce
e
nl
7 - Centre silencer pt
du
an
itte
y li
❑ Separating exhaust
erm
ab
pipes from silencers
ility
ot p
⇒ page 334
wit
, is n
h re

hole
spec
⇒ page 334
es, in part or in w

t to the co
tem free of tension

⇒ page 335 .
rrectness of i
8 - Retaining ring
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9 - Bracket
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10 - Bolt
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13 - Bolt
C py
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❑ 20 Nm
py by
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14 - Trim
Prote AG.
15 - Rear silencer
❑ With exhaust flap control unit -J883- / -J945-
❑ Separating exhaust pipes from silencers ⇒ page 334
❑ Aligning exhaust system free of tension ⇒ page 335 .
330 Rep. gr.26 - Exhaust system

- Edition 12.2017
1.1.2 Assembly overview - silencers, titanium
1 - Centre silencer
⇒ page 334
❑ Removing and installing AG. Volkswagen AG d
⇒ page 334 agen oes
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❑ Aligning exhaust sys‐ rise
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⇒ page 335 . ss a c
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2 - Nuts un
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❑ Qty. 6
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❑ Specified torque
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⇒ page 339
wit
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3 - Exhaust flap control unit 2 -
hole
spec
J945-
es, in part or in w
t to the co
⇒ page 341
4 - Retaining rings
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❑ Qty. 4
5 - Bracket
nform
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❑ Qty. 3
m
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6 - Bolts
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❑ Qty. 3
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❑ 20 Nm
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7 - Rear silencer
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pipes from silencers p by
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⇒ page 334
by lksw
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⇒ page 334
tem free of tension ⇒ page 335 .
8 - Exhaust flap control unit - J883-
9 - Nuts
❑ Qty. 2
❑ 20 Nm
10 - Clamping sleeve
❑ Tighten threaded connections evenly.

- Edition 12.2017
olkswagen AG
en AG. V
1.1.3 Assembly overview - silencers, estate,
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1 - Centre silencer
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spec
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⇒ page 334
tem free of tension
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⇒ page 335 .
l purpos
2 - Retaining ring
nf
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3 - Bracket
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4 - Bolt
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❑ 20 Nm
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⇒ page 337 t. Cop py
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⇒ page 335 . Prote AG.
❑ Tighten threaded con‐

nections evenly.
❑ 20 Nm
6 - Rear silencer
⇒ page 334
tem free of tension
⇒ page 335 .
7 - Bracket
8 - Retaining ring
9 - Bolts
❑ Specified torque ⇒ General body repairs, exterior; Rep. gr. 63 ; Rear bumper; Assembly overview - add-
on parts
10 - Tailpipe
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 63 ; Rear bumper; Rear bumper;
Removing and installing add-on parts
11 - Rear silencer
❑ Separating exhaust pipes from silencers ⇒ page 334
12 - Double clamp

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❑ 20 Nm
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1 - Centre silencer
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⇒ page 334
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⇒ page 335 .
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2 - Retaining rings
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❑ Qty. 2
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3 - Rear silencer
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⇒ page 334
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rig
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⇒ page 335 . cted agen
Prote AG.
4 - Rear silencer
⇒ page 334
tem free of tension
⇒ page 335 .
5 - Bracket
❑ Qty. 2
6 - Bolts
❑ Qty. 3
❑ 20 Nm
7 - Nuts
❑ Qty. 4
❑ 20 Nm
8 - Double clamp
9 - Bracket

- Edition 12.2017
1.2 Removing and installing silencer

Removing
– Loosen bolt connections for front clamp -arrow-.
– If fitted, disconnect connector on exhaust flap control unit
⇒ page 339 .
– Detach mounting -3- from exhaust system at rear.
WARNING
Risk of accidents caused by weight of silencers

♦ A second mechanic is required for removal of the rear si‐
lencer.
– Unscrew bolts -1 and 2-, and remove silencer.

Installing
G. Volkswagen AG d
– Align exhaust system free of stress ⇒ page
lksw
335
agen A . oes
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Specified torques sedb ara
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♦ ⇒ “1.1 Assembly overview -ssilencers”,
au page 329 ra
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un
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1.3 Separating exhaust pipes from silencers

an
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♦ The connecting pipe can be cut through at the cutting point in

pe
ility
order to renew the centre and rear silencers separately.

ot
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♦ The coupling point is marked by an indentation on the circum‐

hole
spec
ference of the exhaust pipe.

es, in part or in w
t to the co

♦ Chain-type pipe cutter - VAS 6254-
rrectness of i
l purpos
nform
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tion in
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Cop py
t. rig
gh ht
♦ Pneumatic sabre saw - VAS 6780- yri
p by
co Vo
by lksw
cted agen
Prote AG.

- Edition 12.2017
Procedure
– Cut through exhaust pipe at right angles at cutting point
-arrows- using chain pipe cutter - VAS 6254- .
– When installing, position centre of clamp -arrow- over cutting

location.
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– Install clamp so that end of bolt -arrow- does not extend be‐
ce
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nl
yond lower edge of clamp. pt

du
an
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– Align exhaust system free of stress ⇒ page 335 . y li

erm
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ility
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spec
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t to the co
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1.4 Aligning exhaust system free of stress

nf
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Procedure
m
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• The exhaust system must be aligned when cold.

n in
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thi
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– Loosen bolt connections for front clamp -arrow-.

t
sd
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rp
cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- Edition 12.2017
– Push exhaust system towards front until preloading at mount‐

ing for exhaust pipe -a- = 5 mm.
– Align rear silencer so that there is an equal distance between

bumper cut-out and exhaust pipes.
– Tighten clamp evenly.
Specified torques
AG. Volkswagen AG d
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1.5 Align end exhaust pipes

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Procedure
ility
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– Align rear silencer so that there is an equal distance between

h re
hole
bumper cut-out and exhaust pipes.

spec
es, in part or in w
• -a- = -a-
t to the co
– Unfasten rear silencer mounting to align tailpipes.

rrectness of i
l purpos
nform
mercia
a
com
tion in
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1.6 Check exhaust system for leaks

s
iva
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rp
cum
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– Start engine and run it at idling speed.

en
ng
t.
yi Co
op
– Seal end exhaust pipes with cloths or plugs, for example, for C py
t. rig
the duration of the leakage test. gh ht
pyri by
Vo
co lksw
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– Check (by listening) points of connection between exhaust Prote
cted AG.
agen
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.

- Edition 12.2017
1.7 Installation position of clamp

Installation position of clamp
– Fit clamp in position shown. Bolt -arrow- must not protrude
beyond lower edge of clamp.
• Threaded connections face towards left.
• Bolt -arrow- must not protrude beyond lower edge of clamp.
lkswage es n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Edition 12.2017
2 Exhaust gas cleaning

⇒ “2.1 Assembly overview - emission control”, page 338
⇒ “2.2 Removing and installing catalytic converter”, page 339
⇒ “2.3 Removing and installing exhaust flap control unit J883 /
J945 ”, page 341
2.1 Assembly overview - emission control
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Bolt
Specified torque and tighten‐ lkswage es n
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ing sequence ⇒ page 339 byV ua
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4 - Nut au ac
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Specified torque and tighten‐

un
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ing sequence ⇒ page 339
an
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erm
ab
5 - Bracket
ility
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wit
❑ For catalytic converter
is n
h re
ole,
6 - Catalytic converter
spec
❑ With front exhaust pipe
t to the co
❑ Protect catalytic con‐
verter from damage by
knocks and impact
rrectne
⇒ page 339
ss o
cial p
f in
tem free of tension
form
mer
⇒ page 335 .
atio
om
7 - Screw-type clamp
n
c
i
or
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te
sd
iva
pr
cum
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fo
⇒ page 339
en
ng
t.
yi Co
❑ Specified torque and Cop py
tightening sequence
t. rig
gh ht
yri
⇒ page 339
p by
co Vo
by lksw
cted agen
8 - Seal
Prote AG.

10 - Nut
Specified torque and tightening sequence ⇒ page 339
11 - Nut
❑ 30 Nm
12 - Front clamp
❑ Align exhaust system free of tension before tightening ⇒ page 335 .

- Edition 12.2017
Exhaust flap control unit – specified torque

Nuts -3- 3 Nm
Note
Renew nuts.
AG. Volkswagen AG d
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Installation position
aut
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of screw-type clip for catalytic converter or a
ss c
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nl
pt
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Catalytic converter - specified torque and tightening sequence

– Tighten bolted connections in stages in the sequence shown:
nf
ercia
or
Stage Screw-type clip/ Specified torque

m
m
atio
nuts
om
n in
or c
1. -1, 3, 4- Screw in by hand as far as stop

thi
te
• It should still be possible to move

sd
iva
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catalytic converter and bracket.

rp
cu
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t.
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2. -2- Tighten screw-type clip to 15 Nm
Co
Cop py
ht. rig
3. -1, 3, 4- Tighten to 20 Nm
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2 Removing and installing catalytic con‐

verter
Removing
Note
♦ The catalytic converter is removed together with the front ex‐

haust pipe.
♦ Fit cable tie in same place when installing.
2. Exhaust gas cleaning 339

- Edition 12.2017

sulation .
– If fitted, remove propshaft ⇒ Propshaft and rear final drive,
Volkswagen R GmbH; Rep. gr. 39 ; Propshaft; Removing and
installing propshaft .
– Remove lambda probe 1 after catalytic converter - GX7-
⇒ page 323 .
– Unscrew bolt -2- and remove screw-type clip.
– Unscrew nuts -1 and 3-.
AG. Volkswagen AG d
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– Unscrew bolts -arrows-. orise nte
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un
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ility
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spec
t to the co
rrectne
– Loosen clamp -arrow-, and push it to rear.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

gen AG
. Volkswagen AG
d
- Edition 12.2017
wa oes
olks not
yV gu
– Unscrew bolts -arrows-,ed b and remove heat shield for drive shaft.
ara
nte
oris eo
th
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew pendulum support bolts -1- from gearbox.
l purpos
– Have a second mechanic slightly push engine/gearbox as‐

sembly towards front end.
nf
ercia
– Detach catalytic converter with front exhaust pipe.
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Installing
by lksw
cted agen
Prote AG.
– Insert screwdriver -2- into recess -arrow- on turbocharger, and
lever out seal -1-.
– Insert new seal.
– Fit catalytic converter to turbocharger and attach screw-type
clip loosely without tightening it.
– Tighten nuts and screw-type clip ⇒ page 339 .
– Align exhaust system free of stress ⇒ page 335 .
Specified torques
2.3 Removing and installing exhaust flap

control unit -J883- / -J945-
Removing
– Slightly lower exhaust system at rear.
2. Exhaust gas cleaning 341

gen AG. Vol,lk4sw
V,
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does chain drive, generation III) Volkswagen R GmbH
swa
- Edition 12.2017 y V olk not
gu
b ara
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ris
– Disconnect electrical
au
tho
connector -2-. e or
ac
ss
– Unscrew nuts -3-, and remove exhaust flap control unit -1-.
ce
le
un
pt
an
d
Installing
itte
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erm
ab
ility
ot p
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Specified torques
h re
ole,
♦ ⇒ Fig. ““Exhaust flap control unit – specified torque”“ ,
spec
page 339
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- Edition 12.2017
AG. Volkswagen AG d
agen
3 Secondary air Vosystem
oes
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⇒ “3.1 Assembly overview thor- secondary air system”, page 343 eo
au ra
c
⇒ “3.2 Removing and sinstalling secondary air pump motor V101
s
ce
le
”, page 344
un
pt
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d
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⇒ “3.3 Removing and installing sender 1 for secondary air pres‐
erm
ab
sure G609 ”, page 344
ility
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⇒ “3.4 Removing and installing secondary air inlet valve N112 ”,
is n
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page 344
ole,
spec
3.1 Assembly overview - secondary air system
t to the co
1 - Air filter housing
rrectne
⇒ page 287
ss o
2 - Connecting cable
cial p
f inform
❑ From secondary air
mer
pump motor - V101- to
atio
m
air filter housing

o
n
c
i
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3 - Connecting cable
te
sd
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❑ From secondary air inlet
pr
cum
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fo
valve - N112- to secon‐
en
ng
t.
dary air pump motor -
yi Co
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V101-
C py
t. rig
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4 - Sender 1 for secondary air cop Vo
by lksw
cted
pressure - G609-
agen
Prote AG.
5 - Seal
❑ Renew after removal of
secondary air inlet valve
- N112-
6 - Secondary air inlet valve -
N112-
⇒ page 344
7 - Bolts
❑ 9 Nm
8 - Electrical connection
❑ For secondary air inlet
valve - N112-
9 - Electrical connection
❑ For sender 1 for secon‐
dary air pressure -
G609-
10 - Nuts
❑ 8 Nm
11 - Secondary air pump motor - V101-
3. Secondary air system 343

- Edition 12.2017
3.2 Removing and installing secondary air

pump motor - V101-
Removing
insulation .
– Open locking element -arrows- and pull off the lines -1- from
secondary air pump motor - V101- -2-.
AG. Volkswagen AG d
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nl
pt
du
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ab
ility
ot p
wit
, is n
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hole
spec
– Separate connector -2- of secondary air pump motor - V101- .
es, in part or in w
t to the co
– Unscrew nuts -arrows-, and remove secondary air pump mo‐
tor - V101- -1- together with bracket.
rrectness of i
Installing
l purpos

Specified torques
nform
ercia
♦ ⇒ “3.1 Assembly overview - secondary air system”,

m
at
page 343
om
ion
c
in t
or
his
ate
do
priv
cum
or
3.3 Removing and installing sender 1 for

f
en
ng
t.
yi Co
secondary air pressure - G609- Cop py
t. rig
gh ht
yri by
Removing
op Vo
by c lksw
cted agen
Prote AG.
– Release fasteners, and pull off sender 1 for secondary air
pressure - G609- -2-.
Installing
Note
Renew O-ring.
3.4 Removing and installing secondary air

inlet valve - N112-
• The flange must not be separated from the secondary air inlet
valve.

- Edition 12.2017
• Always renew secondary air inlet valve together with flange.

Removing
– Move electrical wiring harnesses -1, 2- clear at air pipe.
– Remove bolts -arrows- and detach air pipe.
AG. Volkswagen AG d
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un
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– Disconnect connector -3- from sender 1 for secondary air
ility
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pressure - G609- -1-, and unclip sender.
wit
is n
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– Release both retaining tabs -arrow- of sender 1 for secondary
ole,
spec
air pressure - G609- , and pull sender 1 for secondary air
pressure - G609- -1- off connecting wire -2-.
t to the co
rrectness o
cial p
f inform
mer
atio
– Disconnect connector -3- from secondary air inlet valve -
om
n
N112- -2-.
c
i
or
n thi
te
– Pull off connecting pipe -1-. To do this, press retaining ring
sd
iva
o
r
together on both sides.

p
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove secondary air inlet valve - N112- -1-.
Installing
• Renew seal ⇒ Electronic parts catalogue (ETKA)
Specified torques
♦ ⇒ “3.1 Assembly overview - secondary air system”,
page 343
3. Secondary air system 345

- Edition 12.2017
28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 346
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 347
⇒ “1.3 Removing and installing knock sensor ”, page 348
⇒ “1.4 Removing and installing Hall sender”, page 349
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
350
1.1 Assembly overview - ignition system
1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 8 Nm +90° gen AG
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❑ Removingthandor installing eo
⇒ pagess348
au ra
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3 - Spark plug
nl
pt
du
an
itte
❑ Remove and install us‐

y li
erm
ab
ing spark plug socket

ility
ot p
and extension - 3122

wit
B- .
, is n
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hole
❑ 30 Nm
spec
es, in part or in w
4 - Ignition coil with output

t to the co
stage
❑ Ignition coil 1 with output
stage - N70-
rrectness of i

l purpos
stage - N127-
nf
ercia
stage - N291-
orm
m

atio
m
stage - N292-
o
n in
or c
❑ 10 Nm
thi
te
sd
iva

o
r
rp
cu
⇒ page 347
o
m
f
en
ng
t.
yi Co
5 - Bolt ht. Cop py
rig
❑ 9 Nm rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
⇒ page 349
7 - O-ring
8 - O-ring
346 Rep. gr.28 - Ignition system

- Edition 12.2017

10 - Bolt
❑ 9 Nm AG. Volkswagen AG d
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olksw not
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11 - O-ring ed b ara
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❑ Renew if damaged aut
ho eo
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12 - Engine speed sender - G28-
ce
le
un
pt
❑ Check O-ring for damage.
an
d
itte
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❑ Removing and installing ⇒ page 350 rm
ab
pe
ility
ot
13 - Bolt
wit
, is n
h re
❑ 9 Nm
hole
spec
es, in part or in w
t to the co
1.2 Removing and installing ignition coils
with output stage
rrectness of i
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♦ Puller - T10530-
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Removing
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– If fitted, detach earth wire -1- of ignition coil to be removed,
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and unscrew bolt -arrow-.
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– Release connectors and simultaneously pull all connectors

from ignition coils.
1. Ignition system 347

- Edition 12.2017
– Insert puller - T10530- into hole -1- in ignition coil.

– Turn knurled nut -2- clockwise until puller is fixed in position.
– Using puller - T10530- , carefully pull ignition coil vertically up‐

wards to remove.
Installing
– Press ignition coils onto spark plugs by hand evenly (do not
use tools).
– Tighten ignition coils.
Specified torques
♦ ⇒ “1.1 Assembly overview - ignition system”, page 346
Ignition coil earth wire 9 Nm
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– Pull connector -2- off knock sensor 1 - G61- .

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– Remove actuator for engine temperature regulation - N493-

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⇒ page 239 .
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The knock sensor I - G61- is located under the intake manifold

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348 Rep. gr.28 - Ignition system

- Edition 12.2017
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Installing
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– Note installation position of knock sensor 1 - G61- .

– Install actuator for engine temperature regulation - N493-
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⇒ page 239 .
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1.4 Removing and installing Hall sender
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⇒ “1.4.1 Removing and installing Hall sender G40 ”, page 349
⇒ “1.4.2 Removing and installing Hall sender 3 G300 ”,
page 349
1.4.1 Removing and installing Hall sender -

G40-
Removing
– Remove intake manifold ⇒ page 289 .
– Unscrew bolt -1-, and remove Hall sender -2-.
Installing
– Renew O-ring.
Specified torques
1.4.2 Removing and installing Hall sender 3 -

G300-
Removing
1. Ignition system 349

- Edition 12.2017

– Unscrew bolt -1-, and remove Hall sender -2-.
Installing
– Renew O-ring.
Specified torques
1.5 Removing and installing engine speed

sender - G28-
Removing
sulation .
– Release clip -2- for air intake hose, and pull air intake hose off
throttle valve module - J338- .
– Remove air intake hose downwards.
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– Remove securing bolt -arrow-.

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Installing
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– Install air pipe.
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gr. 66 ; Noise insulation; Assembly overview – noise insula‐

tion .
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Specified torques
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Rep. gr.28 - Ignition system

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Service

Golf aVariant 2015 ➤ , Golf Variant 2017 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B803919C7

3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1.2 Removing and installing upper timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4.3 Installing ball for sliding piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

2.3 Removing ageand

4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

4.5 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

6.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

1.1 Engine number/engine data

♦ ⇒ Maintenance ; Booklet 43.1 ; Vehicle data sticker

Displacement l 1.984 1.984 1.984

Bore ∅ mm 82.5 82.5 82.5

Compression ratio 9.3:1 9.3:1 9.3:1

RON 981) 981) 981)

Ignition/injection system FSI FSI FSI

MPI MPI MPI

Exhaust gas recirculation No No No

Exhaust gas temperature regulation No No No

Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

Codes CJXB CJXC CYFB

Codes CJXD CJXG DJHA

Exhaust gas recirculation No No No

Exhaust gas temperature regulation No No No

Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

Secondary air system No No No

Valves per cylinder 4 4 4

Firing order 1-3-4-2 1-3-4-2 1-3-4-2

• 1) Unleaded petrol RON 95 can also be used, though power

Codes DJHB DJJA DLRA

2 Rep. gr.00 - Technical data

2.1 Safety regulations for working on fuel

The fuel line is under pressure.

Risk of injury due to fuel which is under very high pressure

2.2 Safety measures when working on ve‐

hicles with a start/stop system

Risk of injury due to automatic start of engine on vehicles with