Service Manual

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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
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20 - Fuel Supply yV
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26 - Exhaust System, Emission Controls
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28 - Ignition/Glow Plug 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 © 2015 Volkswagen AG, Wolfsburg D3E800F5F31

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-Cylinder Fuel Injection Engine (1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Transmission and Engine, Disconnecting and Assembling . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Engine, Securing on Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Overview - Subframe Mount, Golf, Eos, Passat, and CC . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Overview - Subframe Mount, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Subframe Mount, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Subframe Mount, Adjusting, Passat from MY 2006 and CC . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Subframe Mount, Adjusting, Rabbit, and Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Subframe Mount, Adjusting, Tiguan g.e.n A .G. ..V.o.lk.sw
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3 Special Tools . . . . . . . . . . .b.y V. . . . . . . . . . . . . . . . . . . . . . . . o.t .gu.a. . . . . . . . . . . . . . . . . . . . .
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13 - Crankshaft, Cylinder Block .. ...................... . . . e.or.ac. . . . . . . . . . . . . 40
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1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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1.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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1.2 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.3 Ribbed Belt Tensioning Damper, Removing and Installing, Passat from MY 2006 and CC
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1.4 Ribbed Belt Tensioner, Removing and Installing, Rabbit and Eos . . . . . . . . . . . . . . . . . . 46
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1.5 Ribbed Belt Tensioner, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1.6 Sub-Assembly Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.7 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.8 Vibration Damper Shaft Seal, Always Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i 59
2 Cylinder Block on Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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2.1 Overview - Transmission Side Sealing Flange and Dual Mass Flywheel/Drive Plate . . . . 62
2.2 Dual Mass Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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2.3 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.4 Transmission-Side Sealing Flange, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 66
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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3.2 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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3.3 Crankshaft Bearing Shells, Allocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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3.4 Needle Bearings, Removing from Crankshaft and Installing . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.5 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.6 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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3.7 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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4 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2 Pistons, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 New Connecting Rod, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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1.1 Overview - Timing Chain Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.2 Camshaft Adjustment Valve 1 N205 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Upper Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.4 Lower Timing Chain Cover, Removing and Installing, Passat and CC . . . . . . . . . . . . . . . . 93
1.5 Lower Timing Chain Cover, Removing and Installing, Rabbit and Eos . . . . . . . . . . . . . . . . 98
1.6 Lower Timing Chain Cover, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Overview - Camshaft Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.8 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.9 Overview - Balance Shaft Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.10 Balance Shaft Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.11 Balance Shaft Intake Side, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.12 Exhaust Side Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.13 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.3 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.4 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.5 Vacuum Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.2 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.3 Camshafts, Checking Axial Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.4 Valve Stem Seals, Always replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.5 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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1.1 Overview - Oil Pan and Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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1.2 Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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1.4 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

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1.5 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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1.6 Oil Pressure Regulation Valve N428 , Removing and Installing, Engine Codes CCZA, CCZB,
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CCZC, CCZD, CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

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2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

3 Oil Filter, Engine Oil Cooler and Oil Pressure Switch, Engine Codes . . . . . . . . . . . . . . . . 217
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3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure Switch F1 . . . . . . . . . . . . . . . . 217
3.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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3.3 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4 Oil Filter, Oil Cooler and Oil Pressure Switch, Engine Codes CCZA, CCZB, CCZC, CCZD,
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CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

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4.1 Overview - Oil Filter and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

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4.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

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4.3 Oil Pressure Switch F1 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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4.4 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 224
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4.5 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.2 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.3 Coolant System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
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2 Coolant Pump, Coolant yThermostat
Volk and Coolant Pipesnot .gu. . . . . . . . . . . . . . . . . . . . . . . . . .. 240
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2.3 Coolant Pump Toothed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Coolant Pump Drive Shaft Seal, Always replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
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2.5 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.6 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 249
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2.7 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
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2.8 Front Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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2.9 Small Coolant Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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2.10 Overview - After-Run Coolant Pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.11 After-Run Coolant Pump V51 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 Radiator and Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
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3.1 Overview - Radiator, Fan Shroud and Radiator Fan, Passat, CC, Golf, and Eos . . . . . . . . 260
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3.2 Radiator Identification Sensor G611 , Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3.3 Overview - Radiator, Fan Shroud and Radiator Fan, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . 262
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3.4 Fan Shroud, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
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3.5 Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing . . . . . . . . . . . . . . . . 265
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3.6 Radiator, Passat, CC, Golf, and Eos, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 265
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3.7 Radiator, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
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20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

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1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 272
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2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3 Fuel Tank, Passat and CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.1 Overview - Fuel Tank, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA and
CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.2 Overview - Fuel Tank, Engine Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3.3 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.4 Fuel Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
4 Fuel Tank, Rabbit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.1 Overview - Fuel Tank, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB and
CDAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.2 Overview - Fuel Tank, Engine Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
4.3 Fuel Tank, Draining, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB and CDAA
........................................................................ 289
4.4 Fuel Tank, Draining, Engine Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5 Fuel Tank, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.1 Overview - Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6 Fuel Tank, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
6.1 Overview - Fuel Tank, Engine Codes CAWA, CAWB, CCZA and CCZB . . . . . . . . . . . . . . 307
6.2 Overview - Fuel Tank, Engine Codes CBFA, CCTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
7 Fuel Supply, Servicing, Passat and CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7.1 Fuel Delivery Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7.2 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
7.3 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8 Fuel Supply System, Servicing, Golf and Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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8.2 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

8.3 Transfer Fuel Pump G6 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
9 Fuel Supply, Servicing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
9.2 Fuel Level Sensor G, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
9.3 Suction Jet Pump, Fuel Filter and Pressure Relief Valve, Removing and Installing . . . . . . 363
9.4 Fuel Level Sensor 2 G169 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
9.5 Fuel Pump Control Module J538 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 366
9.6 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
10 Electronic Engine Output Control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
10.1 Overview - Accelerator Pedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
10.2 Accelerator Pedal Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
11 EVAP Canister System, Passat, CC and Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
11.1 Overview - EVAP Canister System, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA,
CCZB, CCZC, CCZD, CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
11.2 Overview - EVAP Canister System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
11.3 Fuel Tank Ventilation, Checking, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB,
CCZC, CCZD, CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
11.4 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
12 EVAP Canister System, Golf, Eos and Scirocco with Engine Codes CAWA, CAWB, BZB,
CGYA, CCZA, CCZB and CDAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
12.1 Overview - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
12.2 Fuel Tank, Checking Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
13 EVAP System, Rabbit and Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
13.1 Overview Plan - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
13.2 Overview - EVAP System, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
13.3 Overview - EVAP System, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
13.4 EVAP Canister, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
13.5 Leak Detection Pump V144 , Removing and Installing, Golf . . . . . . . . . . . . . . . . . . . . . . . . 406
13.6 Leak Detection Pump V144 , Removing and Installing, Eos . . . . . . . . . . . . . . . . . . . . . . . . 407
13.7 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . .ks. . . . . . . . . . . . . . . . . 407
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1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

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1.2 Hose Connections with Connector Couplings, Assembling . . . . . . . . . . . . . . . . . . . . . . . . 426

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1.3 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

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1.4 Turbocharger Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

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1.5 Turbocharger Vacuum Diaphragm, Adjusting, Engine Codes BZB, CGYA, CDAA and
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CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
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1.6 Turbocharger Vacuum Diaphragm, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 438

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2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

2.1 Overview - Charge Air Cooling System, Passat, CC, Tiguan and Eos . . . . . . . . . . . . . . . . 439
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2.2 Overview - Charge Air Cooling System, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

2.3 Overview - Noise Generator, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
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2.4 Structure-Borne Sound Actuator R214 and Structure Borne Sound Control Module J869
........................................................................ 443
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2.5 Overview - Turbocharging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

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2.6 Charge Air Cooler, Removing and Installing, Golf and Eos . . . . . . . . . . . . . . . . . . . . . . . . 446
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2.7 Charge Air Cooler, Removing and Installing, Passat, and CC . . . . . . . . . . . . . . . . . . . . . . 448
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2.8 Charge Air Cooler, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

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2.9 Charge Air Guide to Noise Generator, Removing and Installing Rabbit . . . . . . . . . . . . . . 450
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2.10 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

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3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
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24 - Multiport
horise Fuel Injection . . . . . . . . . . . . . a.nt.e . . . .
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OBD General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

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2 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

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2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
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2.2 Overview - Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
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2.3 Overview - Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
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2.4 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
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2.5 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
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2.6 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
2.7 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
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2.8 Overview - Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
2.9 Intake Manifold with Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
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2.10 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
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2.11 Fuel Injector Teflon® Seal, Always replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
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2.12 Fuel Injectors, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
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2.13 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
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2.14 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 484
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2.15 Throttle Valve Control Module J338 , Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

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2.16 Overview - High Pressure Pump with Fuel Pressure Regulator Valve N276 . . . . . . . . . . 486
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2.17 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 Components, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
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3.1 Fuel Pressure Sensor G247 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
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3.2 Variable Intake Manifold, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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492
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4 Engine Control Module J623 , Passat and CC through 11/2010 . . . . . . . . . . . . . . . . . . . . 495
4.1 Engine Control Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
4.2 Engine Control Module with Protective Housing, Removing and Installing . . . . . . . . . . . . 496
5 Engine Control Module J623 , Golf and Eos through 11/2008 . . . . . . . . . . . . . . . . . . . . . . 499
6 Engine Control Module J623 , Golf and Eos from 11/2008, CC from 11/2010 . . . . . . . . . . 502
7 Engine Control Module J623 , Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
8 Engine Control Module J623 , Scirocco through 11/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 511
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

1 Exhaust System, Passat and CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
1.1 Overview - Exhaust System, Engine Codes BZB, CAWA, CAWB and CGYA . . . . . . . . . . 518
1.2 Overview - Exhaust System, Engine Code CCTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
1.3 Overview - Exhaust System, Engine Code CBFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
1.4 Center Muffler and Rear Muffler, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
1.5 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
1.6 Clamping Sleeve, Installation Position and Tightening Specification . . . . . . . . . . . . . . . . . . 527
1.7 Catalytic Converters with Front Exhaust Pipe, Removing and Installing . . . . . . . . . . . . . . 528
1.8 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
2 Exhaust System, Rabbit, and Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
2.1 Overview - Exhaust System, Engine Code CAWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
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2.2 Overview - Exhaust System, Golf from MY 2004, and Eos, Engine Codes CCTA . . . . . . 533
2.3 Overview - Exhaust System, Engine Code CBFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
2.4 Overview - Exhaust System, Golf from MY 2009, Engine Codes CCZA and CCZB . . . . . . 538
2.5 Overview - Exhaust System, Golf from MY 2009, Engine Codes CCTA . . . . . . . . . . . . . . 540
3 Exhaust System, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
3.1 Overview - Exhaust System, Engine Codes CCTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
3.2 Overview - Exhaust System, Engine Code CAWA and CAWB . . . . . . . . . . . . . . . . . . . . . . 550
4 Secondary Air Injection System, Engine Code CBFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
4.1 Overview - Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
4.2 Secondary Air Injection Pump Motor V101 , Removing and Installing . . . . . . . . . . . . . . . . 560
4.3 Secondary Air agInjection
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olkswagen AG Valve N112 , Removing and Installing . . . . . . . . . . . . . .
does 561
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28 - Ignition/Glow
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Plug System . . . . . . . . . . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
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1 Ignition System, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
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1.1 Ignition System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

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1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

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1.3 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

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1.4 Ignition Coils with Power Output Stages, Removing and Installing . . . . . . . . . . . . . . . . . . 566
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1.5 Knock Sensor 1 G61 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

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1.6 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

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1.7 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
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3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

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vi Contents
00 – General, Technical Data

1 Engine Number
(Edition 07.2015)
The engine number (“engine codes” and “serial number”) are lo‐
cated at the engine/transmission joint.
The engine code is also stamped on the cylinder block behind the
oil filter.
Vehicles with Four-Digit Engine Codes
Four-letter engine codes beginning with “C” are used. The first
three letters describe the mechanical engine structure and are still
stamped on the engine, as before. The fourth letter describes the
engine torque and output and depends on the engine control
module. Four-digit engine codes are found on the type label and
vehicle data label. It can also be read via the engine control mod‐
ule.
Note
Vehicle data label locations. Refer to ⇒ Maintenance ; Booklet

24.1 ; General Information; Vehicle Data Label .
AG. Volkswagen AG d
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1. Engine Number 1
2 Engine Specifications
Codes CBFA CCTA
Manufactured from
Golf from MY 2004 from 03/2008 from 03/2008
Eos from 05/2008 from 05/2008
Tiguan --- From 01/2008
Scirocco --- ---
Passat from MY 2006 from 03/2008 from 03/2008
CC AG. Volkfrom
swage10/2009
n AG d from 06/2008
agen oes
Golf from MY 2009 olksw from 07/2009 not from 07/2009
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Emissions values rise
SULEV ntee ULEV 2
ho
ut or
Displacement ss
a liters 2.0 ac 2.0
Output kW at RPM 147/5100 147/5100
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Torque Nm at RPM 280/1700 280/1700

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Bore Diameter in mm 82.5 82.5
pe
ility
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Stroke mm 92.8 92.8
wit
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Compression ratio 9.6:1 9.6:1
hole
spec
Research Octane Number (RON) 95 95
es, in part or in w
t to the co
Injection system/ignition system FSI FSI
Ignition sequence 1-3-4-2 1-3-4-2
rrectness of i
Turbocharger, Supercharger Turbocharger Turbocharger
Variable valve timing yes yes
l purpos
Secondary air injection (AIR) yes no

Valves per cylinder 4 4
nform
ercia
Oil pressure control no no

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2 Rep. Gr.00 - General, Technical Data

10 – Engine Assembly
1 Engine, Removing and Installing
⇒ “1.1 Engine, Removing”, page 3 .
⇒ “1.2 Transmission and Engine, Disconnecting and Assem‐
bling”, page 14 .
⇒ “1.3 Engine, Securing on Assembly Stand”, page 16 .
⇒ “1.4 Engine, Installing”, page 16 .
1.1 Engine, Removing

Special tools and workshop equipment required
♦ Pry Lever - 80-200-
♦ Engine Sling - 2024A-
♦ Engine and Gearbox Jack - VAS6931-
♦ Hose Clip Pliers - VAG1921- or Hose Clip Pliers - VAS6362-
♦ Commercially available Step Ladder
♦ Engine Bung Set - VAS6122-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Engine/Gearbox Jack - Engine Support - T10359A- with En‐
gine/Gearbox Jack - Pin - T10359/2-
♦ Transmission Support - 3282-
Note
olkswagen AG
en AG. V
♦ To perform work sequence, the battery ground cable omust
lksw be
ag does
not
disconnected. For this reason check if a coded radio d by Vis instal‐ gu
ara
led. If necessary, obtain anti-theft coding beforehand.
horise nte
eo
ut ra
The engine is removed downward together s with the transmis‐
a
♦ s c
sion.
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le
un
pt
an
d
♦ All cable ties which are loosened or cut open when removing
itte
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rm
engine, must be replaced in the same position when installing

ab
pe
ility
engine.
ot
wit
, is n
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hole
spec
Caution
es, in part or in w
t to the co
When doing any assembly work, especially in the engine com‐

partment, pay attention to the following due to the limited
rrectness of i
space.
l purpos
♦ Route all lines and wires in their original locations.

♦ Make sure that there is sufficient clearance to all moving
nform
ercia
or hot components.
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tion in
– Check DTC memories of all control modules before removing

r
te o
thi
engine. Refer to Vehicle Diagnostic Tester .

s
iva
do
r
rp
– Turn off the ignition and disconnect the ground cable from the
cum
fo
battery. Refer to ⇒ Rep. Gr. 27 ; Battery, Disconnecting and

en
ng
t.
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Connecting; Battery, Disconnecting .
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1. Engine, Removing and Installing 3

– Remove the engine cover. Refer to

⇒ “2.2 Engine Cover, Removing and Installing”, page 135 .
– Remove the air filter. Refer to
⇒ “2.4 Air Filter Housing, Removing and Installing”,
page 465 .
– Remove the battery and battery tray.
– Remove the wiper arms. Refer to ⇒ Rep. Gr. 92 ; Windshield
Wiper System; Wiper Arms, Removing and Installing .
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Trim Moldings and Trim; Plenum Chamber Cov‐
er .
Golf and Eos:
– Remove the plenum chamber bulkhead. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 50 ; Bulkhead; Overview - Bulkhead .
– Disconnect the engine wiring harness connector from the en‐
gine control module. Refer to
⇒ “5 Engine Control Module J623 , gGolfn AGand
. VolkEos
swagthrough
en AG
11/2008”, page 499 . lkswa e does
not
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– Remove the charge air oduct ris to the sound generator, if equip‐
e nte
ped. Refer to auth eo
ra
⇒ “2.9 Charge Air Guide
ss to Noise Generator, Removing and c
Installing Rabbit”, page 450 .
ce
le
un
pt
an
d
itte
Passat CC:
y li
erm
ab
ility
ot p
gine control module. Refer to wit

is n
⇒ “4 Engine Control Module J623 , Passat and CC through h re

ole,
11/2010”, page 495 .

spec
t to the co
Tiguan:
gine control module. Refer to
rrectne
⇒ “7 Engine Control Module J623 , Tiguan”, page 507 .

All:
ss o
cial p
f in
– Release pass-through for engine wiring harness -arrow- and

form
mer
pull off upward.

atio
om
n
c
i
or
n thi
te
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4 Rep. Gr.10 - Engine Assembly

– Remove the E-box cover from the engine compartment by

sliding both latches in direction of -arrow-.
– Disconnect the cable from the generator -A- and the cable
from the battery -B- on the fuse panel.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Disconnect the ground wire on the longitudinal member
spec
-arrow-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
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– Open the wiring guide locking mechanisms on the longitudinal

r
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member -arrows-.
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– Free up the connector -1- and disconnect. t. Cop py
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– Open the underlying wiring guide bracket -2-. yri
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– Remove the engine control module wiring harness out of the

wiring guide and lay it on the engine.
1.8L Vehicles with Manual Transmission:
– Remove the shift mechanism from the transmission. Refer to
⇒ Rep. Gr. 34 ; Selector Mechanism; Selector Mechanism,
Removing and Installing .
lkswage es n
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byV ua
d ran
ir se tee
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a ac
ss
ce
le
– Remove the brace -1-.
un
pt
an
d
itte
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– Remove the clutch slave cylinder -arrows- and move it to the
rm
ab
side. Do not open the line system. pe
ility
ot
wit
, is n
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Caution
hole
spec
es, in part or in w
Do not press the clutch pedal after removing the slave cylinder.
t to the co
Slave cylinder may be damaged by doing this.
rrectness of i
2.0L Vehicles with Manual Transmission:
l purpos

nform
ercia

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a
com
tio
– Clamp off the return hose leading to the master cylinder using
n in
r
the Hose Clamps - Up To 25mm - 3094- .

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– Remove the clamp -arrow- for the line until it stops.

– Pull the line out of the breather/slave cylinder and seal it off.
Caution
Do not press the clutch pedal.
Vehicles with Automatic Transmission n AG. Volkswagen AG do

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– Remove the selector lever cable from the transmission.
ir se
d b Refer ua
ran
to ⇒ Rep. Gr. 37 ; Selector Mechanism, Passat,
tho Passat CC, tee
or
CC and Tiguan, through 11/09/2009 or ⇒ss aRep.
u
Gr. 37 ; Se‐ ac
lector Mechanism, Tiguan from 11/09/2009 .
ce
e
nl
pt
du
an
Tiguan with Automatic Transmission:
itte
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erm
ab
– Remove the transmission oil cooler lines from the transmis‐
ility
ot p
sion. Refer to ⇒ Rep. Gr. 37 .
wit
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Continuation for All Vehicles:
hole
spec
es, in part or in w
t to the co
– Disconnect the connector -2-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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– Remove the upper mounting bolts for the air shroud

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– Loosen the hose clamp -2-.

– Remove the bolt -4-. AG. Volkswagen AG d
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– Disconnect the connectors -arrow- by V and free up the electric
o gu
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WARNING
ce
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un
pt
an
d
itte
The coolant system is under pressure when the engine is
y li
erm
ab
warm.
ility
ot p
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Risk of scalding due to hot steam and hot coolant.
is n
h re
ole,
Reduce pressure by covering the coolant reservoir cap with a
spec
cloth and carefully opening.
t to the co
– Open the coolant reservoir cap.
rrectne
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Noise Insulation .
ss o
cial p
– Remove the front section of the wheel housing liners or the
f in
front wheel housing liners. Refer to ⇒ Body Exterior; Rep. Gr.
form
mer
66 ; Wheel Housing Liner; Front Wheel Housing Liner, Re‐
atio
m
moving and Installing .

o
n
c
i
or
n thi
e
– Remove the charge air hoses -arrows-.

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– Disconnect the connector -1- and remove the lower bolts

-arrows- from the air shroud.
– Remove the air shroud downward.

4-Cylinder Fuel Injection
en AEngine
G. Volksw(1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015
agen AG
ag does
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y Vol gu
– Cover the radiator with ed Protective
b Mat - VAS531003- . ara
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ab
ility
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es, in part or in w
t to the co
rrectness of i
– Remove the bolt -1- and remove the air guide pipe downward.
l purpos
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mercia
at
om
ion
c
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or
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ate
do
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for
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– Disconnect the connector -2- for the Engine Coolant Temper‐
by lksw
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Prote
ature Sensor on Radiator Outlet - G83- .
AG.
– Place the Shop Crane - Drip Tray - VAS6208- under the en‐
gine.
– Drain the coolant. Refer to
⇒ “1.2 Coolant, Draining and Filling”, page 233 .
– Remove coolant hoses -1 and 2-.

WARNING
The fuel supply line is under pressure. Always wear protective

eyewear and protective clothing to prevent injuries and contact
with skin. Place a cleaning cloth around the connection point
before loosening hose connections. Remove the hose con‐
nection carefully to reduce the pressure.
– Disconnect the lines from the fueletransfer.

n AG. Volkswagen AG
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2) Vacuum line tho eo
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3) Fuel supply line
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Golf, Passat, CC, Eos:
an
d
itte
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ab
ility
– Remove the upper coolant hose from the radiator -arrow-.
ot p
wit
is n
Tiguan:
h re
ole,
spec
– Remove the right coolant hose from the radiator and remove
the left coolant hose on the radiator.
t to the co
rrectness o
cial p
f inform
mer
atio
om
All:
n
c
i
or
n thi
e
– Remove the securing bracket slightly in order to remove the

t
sd
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coolant hoses to the heater core for the heater -arrows-.

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Prote AG.
– From above, remove the accessible nuts -arrows- on the front

exhaust pipe connection to the turbocharger.

– Disconnect the vacuum hoses -arrows-.

Vehicles with FWD:
– Remove the right drive axle heat shield -arrows-.

All:
– Remove the drive axles. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .
– Remove the front pipe with the catalytic converter. Refer to
⇒ “1.7 Catalytic Converters with Front Exhaust Pipe, Remov‐
ing and Installing”, page 528 .
Caution
Risk of destroying by reversing the running direction on a used

ribbed belt.
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a felt-tip pen for reinstallation.
– To release the tension on the ribbed belt, turn the tensioner in

direction of -arrow- from underneath.
– Secure the tensioning system using the Locking Pin -
T10060A- . gen AG
. Volkswagen AG
d wa oes
olks not
– Remove the ribbed belt. byV gu
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ris
– Disconnect the connector -1- for the A/C thoCompressor Regu‐ eo
lator Valve - N280- . au ra
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ss
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WARNING
itte
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ility
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Refrigerant can cause serious injury.

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♦ Do not open the A/C system refrigerant circuit.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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cted 1. Engine, Removing and Installing
agen
Prote AG.
4-Cylinder Fuel InjectionenEngine
AG. Volk(1.8L
swagenand
AG 2.0L Engine, Chain Drive) - Edition 07.2015
ag does
ksw not
Vol g
– Remove the screwsed-arrows-
by on the A/C compressor. uaran
oris tee
th or
au ac
Caution
ss
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nl
pt
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an
Risk of damaging the refrigerant lines and hoses.
itte
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ab
♦ Do not bend, twist or stretch the refrigerant lines and ho‐
ility
ot p
ses.
wit
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hole
spec
– Tie up the A/C compressor to the longitudinal member with the
es, in part or in w
t to the co
refrigerant hoses still connected.
Golf & Eos:
rrectness of i
– Remove the radiator. Refer to
⇒ “3.6 Radiator, Passat, CC, Golf, and Eos, Removing and
l purpos
Installing”, page 265 .

– Remove the Generator - C- . Refer to ⇒ Rep. Gr. 27 ; Gen‐
nf
ercia
o
erator .
rm
m
atio
om
n in
All:
or c
thi
te
sd
– Remove the bolt -2- on the bracket for the After-Run Coolant
iva
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Pump - V51- .
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The After-Run Coolant Pump - V51- stays in the installed position. cted agen
Prote AG.
– First remove the bolt -1- and bolts -2 and 3- then remove the
pendulum support.
– If equipped, disconnect the connector -1- on the Oil Level

thermal Sensor - G266- and unclip the bracket -2- on the sub‐
frame.
– Remove/disconnect all wires necessary from engine/trans‐
mission and set aside.
– Disconnect all connection, coolant, vacuum, and intake hoses
from the engine.

Caution
Always use the Engine/Gearbox Jack - Pin - T10359/2- and the

Transmission Support - 3282- . Otherwise the engine can tip
over.
• Install the Engine/Gearbox Jack - Pin - T10359/2- in the En‐

gine/Gearbox Jack - Engine Support - T10359A- and the
AG. Volkswagen
Transmission Support
lksw
agen- 3282- -A-. AG does
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ho
ut or
– Position
ss
a the Engine/Gearbox
Jack - Engine Support - ac
T10359A- -1- on the engine and guide it into the mounts.
ce
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un
pt
an
d
– Close the Transmission Support - 3282- -3- to prevent the en‐

itte
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rm
gine from tipping out of the Engine/Gearbox Jack - Engine
ab
pe
ility
Support - T10359A- .
ot
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es, in part or in w
t to the co
rrectness of i
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– Using the bolt -3-, fasten the Engine/Gearbox Jack - Engine

Support - T10359- -1- to approximately 20 Nm on the cylinder
nform
ercia
block.
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com
tion in
Note
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s
iva
do
The threaded hole for the bolt -1- serves to secure the After-Run
r
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Coolant Pump - V51- .

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t.
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op py
– Install the Engine and Gearbox Jack - VAS6931- on the En‐
t. C rig
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gine/Gearbox Jack - Engine Support - T10359A- .
p by
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– Slightly lift the engine and the transmission.
Prote AG.
Note
Use the Step Ladder - VAS5085- to remove the subframe mount

bolts.
– Remove the subframe mount bolts -arrows- from the engine.

– Remove the subframe mount bolts -arrows- from the trans‐

mission.
Note
♦ Verify that all hose and line connections between engine,

wage
e
transmission and body have been disconnected.
yV
olks s no
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b ara
ed
♦ To prevent damage, carefully guide the engine
thoris and transmis‐ nte
eo
sion when lowering. au ra
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un
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DSG Transmission:
an
d
itte
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• Pay attention to the selector lever cable.
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ab
pe
ility
ot
All:
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– Pull the engine and transmission as far as possible to the front
hole
spec
left and slowly lower it.
es, in part or in w
t to the co
Secure the engine on the Engine and Transmission Holder -
VAS6095- when performing repair work. Refer to
rrectness of i
l purpos
1.2 Transmission and Engine, Disconnect‐

ing and Assembling
nform
ercia

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a
com
tio
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
n in
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te o
thi
♦ Shop Crane - VAS6100-
s
iva
do
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rp
c
♦ Vehicles with automatic transmission: Insert Tool - 18mm -
um
fo
T10179-
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ng
t.
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op py
♦ Vehicles with automatic transmission: Socket - Sw15 - V/175- t. C rig
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♦ Vehicles with automatic transmission: Multipoint Socket -
co Vo
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cted
T10035-
agen
Prote AG.
Separate the Transmission from the Engine:

Requirement
• Engine with the transmission is removed and secured to the
Engine/Gearbox Jack - Engine Support - T10359A- .
– Remove the starter. Refer to ⇒ Rep. Gr. 27 ; Starter, Vehicles
with Manual Transmission or ⇒ Rep. Gr. 27 ; Starter, Vehicles
with Automatic Transmission .
Automatic Transmission and DSG®
– If present, remove the coolant hoses from the transmission oil
cooler and seal off the openings.
AWD Vehicles
– Remove the bevel box (automatic transmission). Refer to ⇒
Rep. Gr. 39
– Remove the bevel box (manual transmission). Refer to ⇒ Rep.
Gr. 39 .
All
– Disconnect and free up all electrical connections from the
transmission to the engine.
– Secure the transmission on the workshop crane using Engine/
Gearbox Support Shackle (2 pc.) - 10-222A/12- , but do not lift
it.

– Remove the upper engine/transmission connecting bolt.

Manual Transmission and DSG®
– Before removing the last connecting bolts, support the trans‐
mission with the workshop crane.
– Remove the lower engine/transmission connecting bolts.
– Separate the transmission from the engine; when doing this,
guide the transmission.
Automatic Transmission
The bolts can be loosened using the Insert Tool - 18mm -
T10179- . When tightening, observe the enlower
AG. Votightening
lkswagen AGspecifi‐
cation. Refer to ⇒ 6-Speed Automatic
lkswagTransmission d es
09M; oRep.not
Vo
Gr. 37 . ed by gu
ara
is nte
or eo
The Multipoint Socket - T10035-
au
th also makes the assembly easier. ra
ss c
– For safety, first install a bolt which is easily accessible.
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nl
pt
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an
– Begin with both lower bolts.
itte
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erm
ab
The hole for removing the converter nuts on the back of the engine
ility
ot p
is covered with a rubber plug.
wit
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– Remove this cap.
hole
spec
es, in part or in w
t to the co
– Remove the six converter nuts -arrow- using the Socket -
Sw15 - V/175- .
rrectness of i
Note
l purpos
♦ Carefully rotate the engine further.

nf
ercia
o
♦ When installing, be especially careful of the engine »while
rm
m
guiding the transmission on the engine«. The starter ring gear

atio
m
can be held steady from the outside using a screwdriver. When

o
n in
or c
installing, the stud bolts are located in the holes on the drive
thi
e
plate.
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en
– Before removing the last connecting bolt, support the trans‐

ng
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mission with the workshop crane. t. Cop py
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– Now remove the last bolt. pyri by
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– Separate the transmission from the engine; when doing this, Prote AG.
guide the transmission.
Note
Pay attention to the converter. It must be removed together with

the transmission.

– During transport, secure the converter -arrow- from falling out,

using for example a wire -A-.
Assembling
Assembly is performed in reverse order of removal; pay attention
to the tightening specifications in each repair manual under
»Transmission, Removing and Installing«.
1.3 Engine, Securing on Assembly Stand

♦ Engine and Gearbox Bracket - VAS6095A-
Requirement
• Engine with the transmission is removed and secured to the n AG. Volkswagen AG do
Engine/Gearbox Jack - Engine Support - T10359A- . lkswage es n
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– Separate the transmission from the engine. Refer to o
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tee
auth or
ac
bling”, page 14 . ss
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nl
pt
– Engage the Engine Sling - 2024A- as shown and lift it out of
du
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the Engine and Gearbox Jack - VAS6931- using the Shop
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Crane - VAS6100- .
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Caution
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spec
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Use securing pins on the hooks and pins to prevent damaging t to the co
the engine. rrectness of i
– Secure the engine on the Engine and Gearbox Bracket -

VAS6095A- .
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ate
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1.4 Engine, Installing
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Subframe mount. Refer to ⇒ “2 Subframe Mount”, page 19 . pyri by
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Install in reverse order of removal while noting the following: Prote AG.

Caution

space.
or hot components.
– Insert new alignment sleeves for centering engine/transmis‐

sion in cylinder block.
lkswage es n
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ss
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es, in part or in w
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orm
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Prote AG.

– Engage the intermediate plate with the sealing flange and then
slide it onto the alignment sleeves -arrows-.
Vehicles with Manual Transmission:
– Lightly coat the drive axle splines with Lubricating Grease - G
000 100- .
– Inspect and install clutch and clutch mechanism. Refer to ⇒
Rep. Gr. 30 ; Clutch Mechanism; Clutch Pedal, Removing and
Installing .
– Make sure there is enough clearance for the subframe and
radiator when installing the engine/transmission assembly.
– Adjust the subframe mount - Passat, CC. Refer to
⇒ “2.4 Subframe Mount, Adjusting, Passat from MY 2006 and
CC”, page 22 .
– Adjust the subframe mount - Rabbit. Refer to
⇒ “2.5 Subframe Mount, Adjusting, Rabbit, and Eos”,
page 25 .
– Adjust the subframe mount - Tiguan. Refer to
⇒ “2.6 Subframe Mount, Adjusting, Tiguan”, page 28 .
Note
wage es n
Subframe mount tightening specifications. Refer to yV
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⇒ “2.1 Overview - Subframe Mount, Golf, Eos, Passat, and CC”, ir se
d b ua
ran
page 19 . utho tee
or
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Electrical connections and wiring routing. Refer to ⇒ Rep. Gr.
le
un
pt
97 .
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– Connect the Vehicle Diagnostic Tester .
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ility
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– Check all DTC memories and erase all DTC memory entries
, is n
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which may have occurred during the assembly.
hole
spec
– Perform a road test.
es, in part or in w
t to the co
– Then a perform vehicle system test and repair any occurring
malfunctions.
rrectness of i
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Note
Generate readiness code if DTC memory was erased. Refer to

nform
ercia
Vehicle Diagnostic Tester “Guided Function”.

m
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tion in
Tightening Specifications:
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Threaded Connection Tightening Spec‐

do
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ification
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Bolts and Nuts M6 10 Nm

t.
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M7 15 Nm
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M8 25 Nm
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Prote
M10 40 Nm
AG.
M12 60 Nm

2 Subframe Mount
AG. Volkswagen AG d
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⇒ “2.1 Overview - Subframe Mount, Golf, Eos, Passat, andVol CC”,
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page 19 . d by ara
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⇒ “2.2 Overview - Subframe Mount, Tiguan”, page
au 21 .
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⇒ “2.3 Subframe Mount, Checking Adjustment”, page 22 .
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CC”, page 22 .
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⇒ “2.5 Subframe Mount, Adjusting, Rabbit, and Eos”, page 25 .
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⇒ “2.6 Subframe Mount, Adjusting, Tiguan”, page 28 . hole
spec
es, in part or in w
2.1 Overview - Subframe Mount, Golf, Eos, Passat, and CC
t to the co
1 - Bolt
rrectness of i
❑ Transmission support to
l purpos
transmission
❑ Tightening specifica‐
nform
ercia
tion. Refer to ⇒ Rep.

Gr. 34 ; Subframe
m
at
om
Mount .
ion
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or
2 - Bolts
his
ate
do
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❑ Pendulum support to
p
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transmission
for
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t.
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tion. Refer to ⇒ Suspen‐ t. C rig
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Rep. Gr. 40 ; Subframe,
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Stabilizer Bar and Con‐
Prote AG.
trol Arms; Overview -

Subframe, Stabilizer
Bar and Control Arms .
3 - Engine Support
4 - Bolt
❑ 40 Nm +180° (1/2 turn)
additional turn
❑ Always replace
❑ Engine support to en‐
gine
5 - Engine Mount
6 - Bolt
❑ 40 Nm + 90° (1/4 turn)
additional turn
❑ Always replace
❑ Engine mount to body
7 - Support
8 - Bolt
❑ 20 Nm + 90° (1/4 turn) additional turn
❑ Always replace
❑ Support to engine mount
9 - Bolt
2. Subframe Mount 19
❑ Always replace
❑ Support to body
10 - Bolt
❑ Always replace
11 - Bolts
❑ Always replace
❑ Engine mount to engine support
12 - Pendulum Support
13 - Bolt
❑ Always replace
❑ Pendulum support to subframe
❑ First install pendulum support to the transmission and then to the subframe
14 - Bolt
❑ Always replace
❑ Transmission mount to transmission support
15 - Bolt
❑ Always replace
❑ Transmission mount to body
16 - Transmission Mount AG. Volkswagen AG d
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❑ The illustration shows the DSG transmission
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17 - Bolt ris tee
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❑ Transmission support to transmission
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❑ Tightening specification. Refer to ⇒ Rep. Gr. 34 ; Subframe Mount .

un
pt
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18 - Transmission Support
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2.2 Overview - Subframe Mount, Tiguan

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1 - Bolt d byV gu
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❑ 20 Nm + 90° (1/4 turn) hor eo
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❑ Always replace
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2 - Bolt
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❑ Always replace
spec
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3 - Engine Mount
4 - Bolt
rrectness of i
❑ 40 Nm + 90° (1/4 turn)
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additional turn
❑ Always replace
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5 - Bolts
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❑ 60 Nm + 90° (1/4 turn)
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6 - Pendulum Support
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7 - Bolt
❑ 100 Nm + 90° (1/4 turn)
additional turn
❑ Always replace
❑ Pendulum support to
subframe
❑ First install pendulum
support to the transmission and then to the subframe
8 - Bolt
❑ Pendulum support to transmission
❑ Tightening specification. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe, Stabilizer
Bar and Control Arms; Overview - Subframe, Stabilizer Bar and Control Arms .
9 - Bolt
❑ Pendulum support to transmission
❑ Tightening specification. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe, Stabilizer
Bar and Control Arms; Overview - Subframe, Stabilizer Bar and Control Arms .
10 - Bolts
❑ Always replace
❑ Transmission mount on the transmission
11 - Bolts
❑ Always replace
❑ Transmission mount to body
12 - Transmission Mount
❑ The illustration shows the DSG transmission version
13 - Engine Support
14 - Bolts
❑ 40 Nm +180° (1/2 turn) additional turn
❑ Always replace
❑ Engine support to engine
2.3 Subframe Mount, Checking Adjustment

There must be a distance -a- of at least 10 mm present between wagen AG. Volkswagen AG doe
engine support and right longitudinal member. yV
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Casting edge on engine support -2- must stand parallelho to the
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– If the conditions are not met, then adjust the subframe mount.
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Refer to ⇒ “2 Subframe Mount”, page 19 .
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2.4 Subframe Mount, Adjusting, Passat
from MY 2006 and CC
rrectness of i
l purpos
Note
nform
ercia
If the subframe mount will only be adjusted on the engine side,

m
at
om
an Engine Support - Bracket w/Spindle and hook - 10-222A/10-
ion
c
on the engine side is enough. It is not necessary to remove the
in t
or
air filter, battery and battery tray.
his
ate
do
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or

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♦ C py
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♦ Engine Support Bridge - 10-222A- copy Vo
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Prote
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
AG.
(quantity: 2)
♦ Engine Support Bridge - Engine Bracket - 10-222A/1-
Adjusting
Proceed as follows:
page 465 .

AG. Volkswagen AG d
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Risk of destroying electronic componentsauwhen
o
th disconnecting eo
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the battery. ss c
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♦ Follow the steps for disconnecting the battery.
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– With the ignition switched off, disconnect the ground cable
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-arrow- on the battery.
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hole
spec
– Remove the battery. Refer to ⇒ Rep. Gr. 27 ; Battery, Re‐
es, in part or in w
moving and Installing; Battery, Removing and Installing .
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Remove the battery tray -arrows-.
in t
or
his
ate
– Position the Engine Support Bridge - 10-222A- with the fol‐
do
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lowing tool parts:

p
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for
en
ng
t.
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Cop py
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rig ht
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Prote AG.
Passat:
♦ Engine Support Bridge - Engine Bracket - 10-222A/1- (quan‐
tity: 2)
(quantity: 2)
CC:
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
(quantity: 2)
(quantity: 2)
Note agen
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♦ The Engine Supportrised
Bridge - Engine Support Feet - 10-222A/
nte
8- must not beut placed on the fender bolting plates or they could
ho eo
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get damaged.
s a c
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♦ The Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- is
pt
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necessary, so that the engine can be lifted into installation po‐

itte
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sition and not »tilted«.
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All:
h re
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spec
– Support the engine with the transmission but do not lift it.
t to the co
– Replace the subframe mount bolts -arrows- on the engine side
one after the other if this was not already performed with the
engine was installed and tighten them by hand.
rrectness o
cial p
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mer
atio
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n
c
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pr
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Vehicles with Manual Transmission: C py
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– Replace the subframe mount bolts -arrows- on the transmis‐
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sion side one after the other if this was not already performed cted agen
Prote AG.
with the engine was installed and tighten them by hand.
Vehicles with Automatic Transmission

sion side one after the other if this was not already performed
All:
– Loosen left and right support arm bolts approximately two
turns.
– Adjust the subframe mount and hand-tighten the bolts.

• There must be a distance -a- of at least 10 mm present be‐

tween engine support and right longitudinal member.
• Casting edge on engine support -2- must stand parallel to the
support arm -1-.

• On the transmission side, the edges of the support arm -1- and
transmission mount -2- are parallel.
• Dimension -x- same size on both sides of bracket.

• Pay attention that on the transmission side, the edges of the
support arm -A- and transmission mount -B- are parallel.
All: lkswage es n
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– ed
Tighten the subframe frame bolts to the requiredoristightening ran
tee
specification. Refer to auth or
ac
⇒ “2.1 Overview - Subframe Mount, Golf, Eos,
ss Passat, and
CC”, page 19 .
ce
le
un
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Install in reverse order of removal.

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2.5 Subframe Mount, Adjusting, Rabbit, and wit

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Eos
hole
spec
es, in part or in w
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Note
rrectness of i
If the subframe mount will only be adjusted on the engine side,

an Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
l purpos
on the engine side is enough. It is not necessary to remove the

air filter, battery and battery tray.
nform
ercia

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com
tion in
♦ Engine Support Bridge - 10-222A-

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thi

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(quantity: 2)
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Cop py
♦ Torque Wrench 1331 5-50Nm - VAG1331-
t. rig
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Prote AG.
♦ Golf: Engine Support Bridge - Gearbox Adapter - 10-222A/13-
♦ Eos, Scirocco: Engine Support Bridge - Engine Bracket -

10-222A/1- agen
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Adjusting ed by gu
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Proceed as follows: aut
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ab
ility
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page 465 .
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– Remove the charge air duct to the sound generator, if equip‐ hole
spec
ped. Refer to
es, in part or in w
t to the co
⇒ “2.9 Charge Air Guide to Noise Generator, Removing and
rrectness of i
Caution
l purpos
Risk of destroying electronic components when disconnecting

the battery.
nform
ercia

m
at
om
ion
c
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or
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e

at
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p
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moving and Installing; Battery, Removing and Installing . t. Cop py
rig
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lowing tool parts:

Golf: AG. Volkswagen AG d

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♦ Engine Support Bridge - Gearbox d by Adapter - 10-222A/13-
V gu
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(quantity: 2) orise nte
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♦ Engine Support - Bracket
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w/Spindle and Hook - 10-222A/10- c
(quantity: 2)
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pt
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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- (quan‐
itte
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tity: 2)
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spec
es, in part or in w
t to the co
Eos and Scirocco:
♦ Engine Support Bridge - Engine Bracket - 10-222A/1- (quan‐
rrectness of i
tity: 2)
l purpos

(quantity: 2)
nform
ercia

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Note
thi
s
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do
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♦ The Engine Support Bridge - Engine Bracket - 10-222A/1-
um
fo
en
g
must not be placed on the fender bolting plates, otherwise they

n
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could get damaged. Cop py
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♦ The Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- is p by
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AG.
All:
– Replace the subframe mount bolts -arrows- on the engine side

one after the other if this was not already performed with the
engine was installed and tighten them by hand.

AG. Volkswagen AG d
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golfau2009
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s
4-Cylinder Fuel Injection Engine (1.8L and 2.0L
s Engine, Chain Drive) - Edition 07.2015
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pt
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ab
ility
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All:
hole
spec
es, in part or in w
turns.
t to the co
rrectness of i
l purpos
nform
• There must be a distance -a- of at least 10 mm present be‐ mercia
at
om
ion
c
in t
or
his
e
support arm -1-.

at
do
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c
um
for
en
ng
t.
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Prote AG.
• On the transmission side, the edges of the support arm -1- and

• Pay attention that on the transmission side, the edges of the
support arm -A- and transmission mount -B- are parallel.
All:
– Tighten the subframe frame bolts to the required tightening
specification. Refer to
⇒ “2.1 Overview - Subframe Mount, Golf, Eos, Passat, and
CC”, page 19 .
2.6 Subframe Mount, Adjusting, Tiguan
Note
Always use two Engine Support - Bracket w/Spindle and hook -

10-222A/10- , since the Engine Support Bridge - 10-222A- tends
to »tip«.


♦ Engine Support Bridge - Sub-Frame Adapter - 10-222A/22-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3- (quan‐
tity: 2)
(quantity: 2)
♦ For automatic transmissions: Lifting Eyebolt - 3368-
Adjusting
Proceed as follows:
page 465 .
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Caution d byV ua
ran
ir se tee
tho
Risk ofdestroying electronicau components when disconnecting or
ac
the battery. ss
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pe
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tion in

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– Install the Lifting Eyebolt - 3368- into the transmission as
shown.

lowing tool parts:
(quantity: 2)
tity: 2)
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♦ Engine/Gearbox eSupport
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t to the co

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lowing tool parts:

cial p
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mer
(quantity: 2)
atio
om
n
c

i
or
n thi
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tity: 2)
t
sd
iva
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pr

um
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(quantity: 2)
en
ng
t.
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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- t. C rig
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All:
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4-Cylinder Fuel Injection Engine (1.8L eand 2.0L Engine, Chain Drive) - Edition 07.2015
n AG. Volkswagen AG
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– Replace the subframe mount bolts -arrows- ed
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y ara
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one after the other if this was not already
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engine was installed and tightens athem by hand. ra
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ility
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es, in part or in w
t to the co
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nf
ercia
orm
m
atio
om
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or c
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te
sd
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en
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– Replace the subframe mount bolts -arrows- one after the other
by c lksw
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(if the was not already performed with the engine was instal‐
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led) and hand tighten.

All:
turns.
Subframe Mount on Engine Side:
• There must be a distance -a- of at least 10 mm present be‐

support arm -1-.
4-Cylinder Fuel Injection Engine
gen AG
. Volk(1.8L
swagenand
AG d2.0L Engine, Chain Drive) - Edition 07.2015
wa oes
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Subframe Mount on Transmission
ed b Side: ara
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• On the transmission
aut
side, the edges of the support arm -1- and or ac
ss
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pt
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ab
– Tighten the subframe frame bolts to the required tightening
ility
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specification. Refer to
wit
is n
⇒ “2.2 Overview - Subframe Mount, Tiguan”, page 21 .
h re
ole,
spec
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3 Special Tools
Special tools and workshop

equipment required
♦ Engine and Transmission
Holder - VAS6095-
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3. Special Tools 33
♦ Pry Lever - 80-200-

♦ Engine and Gearbox Jack -
VAS6931-
♦ Hose Clip Pliers -
VAG1921-
VAS6362-
♦ Step ladder such as Step
Ladder - VAS5085-
♦ Engine Bung Set -
VAS6122-
♦ Shop Crane - Drip Tray -
VAS6208-
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♦ Engine/Gearbox Support
Shackle - 10-222A/12-
♦ Vehicles with an automatic
transmission: Insert Tool -
18mm - T10179-
transmission: Socket -
Sw15 - V/175-
transmission: Multipoint
Socket - T10035-
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3. Special Tools 35
4-Cylinder Fuel Injection Engine (1.8L and 2.0L G. VolkswaChain
gen AEngine,
gen AG
Drive)
does - Edition 07.2015
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Shackle - 10-222A/12-
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5-50Nm - VAG1331-
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40-200Nm - VAG1332-
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♦ Engine Support Bridge -
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Gearbox Adapter -
10-222A/13-
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10-222A-
Sub-frame Adapter -
10-222A/22-
Engine Support 3 -
10-222A/3- quantity: 2
10-222A/10- quantity: 2
Shackle - 10-222A/12-
♦ For automatic transmis‐
sion: Lifting Eyebolt - 3368-
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3. Special Tools 37
♦
10-222A-
♦ Engine Support - Bracket n AG. Volkswagen AG do
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♦ Engine/Gearbox Jack - Engine Support - T10359A- with En‐

gine/Gearbox Jack - Pin - T10359/2-

♦ Transmission Support - 3282-
♦ Protective Mat - VAS531003-
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3. Special Tools 39
13 – Crankshaft, Cylinder Block

1 Cylinder Block, Belt Pulley Side
⇒ “1.1 Overview - Ribbed Belt Drive”, page 40 .
⇒ “1.2 Ribbed Belt, Removing and Installing”, page 42 .
⇒ “1.3 Ribbed Belt Tensioning Damper, Removing and Installing,
Passat from MY 2006 and CC”, page 43 .
⇒ “1.4 Ribbed Belt Tensioner, Removing and Installing, Rabbit
and Eos ”, page 46 .
⇒ “1.5 Ribbed Belt Tensioner, Removing and Installing, Tiguan”,
page 48 .
⇒ “1.6 Sub-Assembly Bracket, Removing and Installing”,
page 52 .
⇒ “1.7 Vibration Damper, Removing
en AG. V
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kswagen AG page 54 .
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⇒ “1.8 Vibration Dampery V Shaft Seal, Always Replace”,
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ling. Refer to
hole
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⇒ “1.7 Vibration Damp‐

es, in part or in w
er, Removing and In‐

t to the co
stalling”, page 54 .
2 - O-Ring
rrectness of i
❑ Always replace
l purpos
3 - Bolt
❑ 150 Nm + 90° (1/4 turn)
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additional turn
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❑ Always replace
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4 - Ribbed Belt
❑ Check for wear
❑ Do not kink
40 Rep. Gr.13 - Crankshaft, Cylinder Block

Caution
Risk of destroying by re‐
versing the running di‐
rection on a used ribbed
belt.
Before
♦ removing the rib‐
bed belt, mark the run‐
ning direction with chalk
or a felt-tip pen for rein‐
stallation.
❑ Removing and installing. Refer to ⇒ “1.2 Ribbed Belt, Removing and Installing”, page 42 .
❑ When installing, make sure it is seated correctly on the belt pulleys
5 - Ribbed Belt Tensioner
❑ To release tension on ribbed belt, pivot using a wrench.
❑ Secure using the Locking Pin - T10060A-
❑ Tensioning device for Ribbed Belt. Refer to
⇒ Fig. ““Ribbed Belt Tensioner Individual Components”“ , page 42
❑ Removing and Installing, Passat and CC. Refer to
⇒ “1.3 Ribbed Belt Tensioning Damper, Removing and Installing, Passat from MY 2006 and CC”,
page 43 .
❑ Removing and Installing, Rabbit, Eos and Scirocco. Refer to
⇒ “1.4 Ribbed Belt Tensioner, Removing and Installing, Rabbit and Eos ”, page 46 .
❑ Removing and Installing, Tiguan. Refer to
⇒ “1.5 Ribbed Belt Tensioner, Removing and Installing, Tiguan”, page 48 .
6 - Sub-Assembly Bracket
❑ With Oil Pressure Switch - F1- , oil filter and engine oil cooler
❑ Sub-assembly bracket, removing and installing. Refer to
⇒ “1.6 Sub-Assembly agen Bracket, Removing
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ed Oil Cooler, Removing and Installing”, nte page 218 .
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9 - Bolt
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❑ 23 Nm
spec
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10 - Bolt
t to the co
❑ Tightening sequence. Refer to ⇒ Fig. ““Sub-Assembly Bracket Tightening Sequence”“ , page 42

11 - A/C Compressor
rrectness of i
❑ Do not remove or disconnect refrigerant lines

l purpos
❑ Removing and installing. Refer to ⇒ Rep. Gr. 87 .

12 - Bolt
nf
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❑ 25 Nm
m
atio
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13 - Alignment Sleeve
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1. Cylinder Block, Belt Pulley Side 41

Ribbed Belt Tensioner Individual Components

1- Ribbed Belt Tensioner
2- Support
3- Sub-Assembly Bracket
4- Centering Bracket
5- Bolt
Sub-Assembly Bracket Tightening Sequence

– Mount the sub-assembly bracket and then mount the bolts
-4-.
– Tighten bolts in -1 to 5- sequence in three stages as follows:
1. Tighten bolts hand-tight.
2. Tighten the bolts to 20 Nm.
3. Turn the bolts an additional 90° (1/4 turn).
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– Remove the right air guide hose -arrows-.

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– Remove the ribbed belt.

Installing
Install in reverse order of removal and note the following:
Note
Before installing ribbed belt, the generator and A/C compressor

must be securely installed.
– First mount the ribbed belt on the crankshaft pulley, then on

the A/C compressor and generator.
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– Turn the tensioner slightly with wrench and remove the Lock‐
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1.3 Ribbed Belt Tensioning Damper, Re‐

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♦ Passat: Engine Support Bridge - Engine Bracket - 10-222A/1-
♦ CC: Engine Support Bridge - Engine Support Feet - 10-222A/
8-
♦ Locking Pin - T10060A-
Removing
Proceed as follows:


– Remove the front part of the right wheel housing liner. Refer
to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front
Wheel Housing Liner, Removing and Installing .
pendulum support.
Pump - V51- .
lowing tool parts:
Passat:
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n AGBracket
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44
Prote AG.
Rep. Gr.13 - Crankshaft, Cylinder Block
CC:
(quantity: 2)
Note
♦ The Engine Support Bridge - Engine Support Feet - 10-222A/

8- must not be placed on the fender bolting plates or they could
get damaged.
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– Tensionhoris the engine with the spindle. nte
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the sub-assembly bracket.

m
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• Tightening specification. Refer to

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• Pay attention to the centering sleeve -4-.
– Adjust the subframe mount. Refer to

CC”, page 22 .

1.4 Ribbed Belt Tensioner, Removing and

Installing, Rabbit and Eos
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Proceed as follows:
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– Remove the charge air duct to the sound generator, if equip‐
, is n
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ped. Refer to
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove the front part of the right wheel housing liner or loosen
the one-piece wheel housing liners. Refer to ⇒ Body Exterior;
l purpos
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .
nform
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m
at
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Pump - V51- .

Golf:
lowing tool parts:
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/13-
Eos and Scirocco:

lowing tool parts:
G. Volkswagen
♦ Engine/Gearbox Support Shackle (2agpc.)
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rrectness of i
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Installing, Tiguan
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Note
Always use two Engine Support - Bracket w/Spindle and hook -

10-222A/10- , since the Engine Support Bridge - 10-222A- tends
to »tip«.

tity: 2)
(quantity: 2)
Removing
Proceed as follows:
– Remove the right front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel
Housing Liner, Removing and Installing .

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rrectness of i
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– Mark the position of the driveshaft with flexible disc to the drive Cop py
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bevel box.
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To loosen or tighten, counterhold the driveshaft on the rear final

drive.

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shown.

lowing tool parts:
(quantity: 2)
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♦ Lifting Eyebolt - 3368-
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♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10- rig ht
py by
(quantity: 2)
co Vo
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cted agen
Prote AG.
All:



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pe
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spec
Installing
es, in part or in w
t to the co
rrectness of i
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nform
ercia
on the support into the hole in the sub-assembly bracket.
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tion in

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iva
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⇒ “2.6 Subframe Mount, Adjusting, Tiguan”, page 28 .

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1.6 Sub-Assembly Bracket, Removing and Cop py
ht. rig
ht
Installing
rig by
copy Vo
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cted agen
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Removing
AG.
Proceed as follows:
ped. Refer to
– Remove the generator. Refer to ⇒ Rep. Gr. 27 ; Generator .

– Disconnect the connector -1- for the A/C Compressor Regu‐

lator Valve - N280- .
WARNING
Refrigerant can cause serious injury.

♦ Do not open the A/C system refrigerant circuit.
– Remove the screws -arrows- on the A/C compressor.
Caution
Risk of damaging the refrigerant lines and hoses.

♦ Do not bend, twist or stretch the refrigerant lines and ho‐
ses.
AG. Volkswagen AG d
agen oes
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ara
– Tie up the A/C compressor to the longitudinal
rised member with the nte
refrigerant hoses still connected. utho eo
ra
s a c
s
– Remove the bolt -arrow- for the oil dipstick tube.
ce
le
un
pt
an
d
itte
y li
– Remove the bolts -1 through 5- and pull off the accessory as‐
erm
ab
sembly bracket from the coolant pump housing.
ility
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is n
Installing
h re
ole,
spec
Note
t to the co
♦ Replace the bolts that were tightened with an additional turn.
rrectne
♦ Replace the O-rings and seals.
ss
– Coat the O-rings -4- with coolant.
o
cial p
– Install the connection -2- into the coolant pump housing -3-. f inform
mer
atio
om
n
c
i
or
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te
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op py
– Slide the sub-assembly bracket -1- onto the connections -2-.
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ht ht
rig by
copy Vo
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Prote AG.

– Mount the sub-assembly bracket and then mount the bolts

-4-.
– Tighten bolts in -1 to 5- sequence in three stages as follows:
1. Tighten bolts hand-tight.
2. Tighten the bolts to 20 Nm.
3. Turn the bolts an additional 90° (1/4 turn).
The rest of the assembly is basically a reverse of the removal.

When at the same time, note the following:
♦ Tightening specifications. Refer to
♦ Install the A/C compressor. Refer to ⇒ Rep. Gr. 87 .
♦ Install the generator. Refer to ⇒ Rep. Gr. 27 ; Generator .
1.7 Vibration Damper, Removing and Instal‐

ling
♦ Counterhold - Vibration Damper - T10355-
♦ Vibration Damper Assembly Tool - T10531-
Individual components of the Vibration Damper Assembly Tool -
T10531- :
♦ Vibration Damper Assembly Tool - Counterhold Tool -
T10531/1-
♦ Vibration Damper Assembly aTool - .Tensioning
gen AG Pins
Volkswagen AG
does-
T10531/2- Volksw not
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♦ Vibration DamperoriAssembly
se Tool - Turning Over Tool - tee
T10531/3- auth or
ac
ss
♦ Vibration Damper Assembly Tool - Knurled Nut - T10531/4-
ce
le
un
pt
an
d
itte
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ab
Note
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ility
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The vibration damper bolt -A- connects the vibration damper -1-
h re
hole
timing chain sprocket -2- and the crankshaft -3-. Before removing
spec
the bolt, the chain sprocket must be secured to the crankshaft as

es, in part or in w
t to the co
described as follows.
Removing
rrectness of i

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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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.

– Remove the right wheel housing liner. Refer to ⇒ Body Exte‐

rior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing
Liner, Removing and Installing .
– Remove the bolts -arrows-.
– Open the clamps -1 and 2- and remove the air guide pipe.
– Remove the Locking Pin - T10060A- from the ribbed belt ten‐
sioner.
– Rotate the vibration damper using the Counterhold - Vibration

Damper - T10355- into the “TDC” position -arrow-.
• The notch on the vibration damper must align with the arrow
marking on the lower timing chain cover.
• The marking for the cover is located in the »four-o'clock posi‐
tion«.
Caution
The vibration damper bolt can only be loosened maximum 1/

2 turn. AG. Volkswagen
n AG do
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by ua
ed ran
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– au
tho
Loosen the vibration damper bolt approximately 1/ turn, to do
2 or
ac
ss
this use the Counterhold - Vibration Damper - T10355- .
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pt
du
– If the vibration damper is turned, correct it to the TDC point.
an
itte
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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 the two bolts -arrows- for the timing chain cover. The
l purpos
bolts must be replaced.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Place the Vibration Damper Assembly Tool - Counterhold Tool

- T10531/1- as shown on the vibration damper and tighten
hand-tight using the knurled bolt -arrows-.
– Remove the vibration damper bolt completely.
– Check if the Vibration Damper Assembly Tool -Turning Over

Tool - T10531/3- -A- can be easily pushed over the clamping
piece -B-. Turn the adjusting bolt -arrow-.
Note
G. Volkswagen
Do not turn the adjusting bolt further, otherwise
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AG do
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olks
Damper Assembly Tool - Tensioning by Pins - T10531/2- becomes
V ot g
ua
jammed when installing the crankshaft.
o
ir se
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te
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au ra
c
ss
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nl
pt
du
an
itte
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erm
– Install the Vibration Damper Assembly Tool - Tensioning Pins

ab
ility
- T10531/2- in the crankshaft and with a 12 mm open end
ot p
wit
wrench -A- tighten hand-tight.
, 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
– Tighten the adjusting bolt -A- hand-tight. From this the chain
om
sprocket is secured to the crankshaft.

n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
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Cop py
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pyri by
Vo
co lksw
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cted agen
Prote AG.

– Remove the knurled bolt -arrows-. Remove the Vibration

Damper Assembly Tool - Counterhold Tool - T10531/1- and
vibration damper -A-.
AG. Volkswagen AG d
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If the Crankshaft Should Be Turned Without the Vibration Damper s
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– Place the Vibration Damper Assembly Tool - Turning Over
an
itte
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Tool - T10531/3- -A- on the tensioning pins while doing so pay
erm
ab
attention to the chain sprocket tooth contour. The flat side of
ility
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the top of the tool sits in TDC. Tighten the Vibration Damper
wit
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Assembly Tool - Turning Over Tool - T10531/3- with the Vi‐
h re
hole
bration Damper Assembly Tool - Knurled Nut - T10531/4-
spec
-B-.
es, in part or in w
t to the co
rrectness of i
l purpos
– The crankshaft can now be turned on the hex fitting -arrow-.
nform
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at
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ate
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en
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t.
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Cop py
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Prote AG.
Install the Vibration Damper:

– If necessary remove the Vibration Damper Assembly Tool -
Knurled Nut - T10531/4- -B- and the Vibration Damper As‐
sembly Tool - Turning Over Tool - T10531/3- -A- from the
tensioning pins.

– Secure the vibration damper in TDC, while doing this pay at‐
tention to the tooth contour of the chain sprocket -arrow-.
AG. Volkswagen AG d
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– Place the Vibration isedDamper
b Assembly Tool - Turning Over
ara
nte
Tool - T10531/3- hor
-A- on the tensioning pins while the hex fittingeo
ut
points to thess vibration damper. Install the Vibration Damper r ac
a
Assembly Tool - Knurled Nut - T10531/4- -B-, while doing this
ce
le
un
move the vibration damper slightly back and forth, to check in
pt
an
d
itte
the vibration damper is seated correctly in the tooth contour.
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ab
Tighten the collar nut, until the vibration damper can no longer
pe
ility
be turned.
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Place the Vibration Damper Assembly Tool - Counterhold Tool rrectness of i
- T10531/1- as shown on the vibration damper and tighten
l purpos
hand-tight using the knurled bolt -arrows-.

nform
mercia
a
com
tion in
r
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thi
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iva
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Cop py
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– Remove the Vibration Damper Assembly Tool - Knurled Nut -
lksw
cted agen
Prote
T10531/4- -A- and loosen the adjusting bolt -B-. Remove the
AG.
Vibration Damper Assembly Tool - Tensioning Pins -

T10531/2- and remove with Assembly Tool - Turning Over
Tool - T10531/3- .

– Install a new vibration damper bolt with an oiled O-ring -1-

hand-tight.
– Remove the knurled bolt -arrows- and remove the Vibration

Damper Assembly Tool - Counterhold Tool - T10531/1- .
AG. Volkswagen AG d
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– Tighten vibration damper bolt using the Counterhold - Vibra‐

h re
ole,
tion Damper - T10355- . spec

– Install new bolts -arrows-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Further assembly is performed the reverse order of the removal.

t
sd
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cum
Tightening Specifications
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♦ Refer to ⇒ “1.1 Overview - Ribbed Belt Drive”, page 40
Co
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cted agen
Prote AG.
1.8 Vibration Damper Shaft Seal, Always

Replace
♦ Seal Installer - Crankshaft - T10354-
♦ Press Piece - Gearbox - T10375-


from the Vibration Damper Assembly Tool - T10531-
Removing
– Remove the vibration damper. Refer to
⇒ “1.7 Vibration Damper, Removing and Installing”, page 54 .
• The Vibration Damper Assembly Tool - Tensioning Pins -
T10531/2- is installed.
– Remove the seal -arrow- with the Seal Installer - Crankshaft -
T40274- .
AG. Volkswagen AG d
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Installing Volksw
oes
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– Clean the contact and sealing surface. orise nte
eo
th
u ra
– Push the seal -arrow- on the Seal Installer - Crankshaft
ss a - c
T10354- .
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nl
pt
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an
• The closed side of the seal points to the Seal Installer - Crank‐
itte
y li
erm
shaft - T10354- .
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Push the seal -arrow- with the Seal Installer - Crankshaft -
rrectness of i
T10354- on the Vibration Damper Assembly Tool - Tensioning
Pins - T10531/2- and place on the lower timing chain cover.
l purpos
– Additionally attach the Press Piece - Gearbox - T10375- and

install the Vibration Damper Assembly Tool - Knurled Nut -
nform
ercia
T10531/4- .
m
at
om
– Tighten the Vibration Damper Assembly Tool - Knurled Nut -

ion
c
T10531/4- with a 21 mm open end wrench, until the seal is

in t
or
pressed in all the way.

his
ate
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Note
n
t.
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Cop py
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♦ Replace the vibration damper bolt.
ht
pyri by
Vo
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by
♦ Replace the O-ring.
cted agen
Prote AG.

Note the following:

– Install the vibration damper. Refer to

lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
CC 2010 ➤ , Eos 2006 ➤ris,edGolf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ran ➤ , ...
tee
o
au Engine (1.8L and 2.0L Engine, Chain Drive) -orEdition
th
ac 07.2015
ss
ce
le
un
pt
2 Cylinder Block on Transmission Side
an
d
itte
y li
rm
ab
pe
⇒ “2.1 Overview - Transmission Side Sealing Flange and Dual
ility
ot
Mass Flywheel/Drive Plate”, page 62 .
wit
, is n
h re
⇒ “2.2 Dual Mass Flywheel, Removing and Installing”,
hole
spec
page 63 .
es, in part or in w
t to the co
⇒ “2.3 Drive Plate, Removing and Installing”, page 64 .
⇒ “2.4 Transmission-Side Sealing Flange, Removing and Instal‐
rrectness of i
ling”, page 66 .
l purpos
2.1 Overview - Transmission Side Sealing Flange and Dual Mass Flywheel/
Drive Plate
nform
mercia
a
com
t
1 - Cylinder Block
ion in
r
❑ Crankshaft, removing
te o
thi
and installing. Refer to
s
iva
do
⇒ “3.1 Overview -
r
rp
cum
fo
Crankshaft”, page 69 .
en
ng
t.
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❑ Piston and connecting Cop py
rod, disassembling and
t. rig
gh ht
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assembling. Refer to
p by
co Vo
by lksw
⇒ “4.1 Overview - Piston Prote
cted AG.
agen
and Connecting Rod”,
page 76 .
2 - Alignment Pin
❑ Not installed
3 - Transmission Side Sealing
Flange
❑ With seal
❑ Replace only as a com‐
plete unit.
ling. Refer to
⇒ “2.4 Transmission-
Side Sealing Flange,
Removing and Instal‐
ling”, page 66 .
4 - Bolt
❑ Tightening sequence.
Refer to
⇒ Fig. ““Transmission
Side Sealing Flange,
Tightening Sequence”“ ,
page 63
5 - Intermediate Plate
❑ Must be located on
alignment sleeves
❑ Be careful not to dam‐
age or bend when installing
❑ Is hooked in at sealing flange. Refer to ⇒ Fig. ““Installing the Intermediate Plate”“ , page 63
6 - Bolt
❑ Always replace
❑ For dual-mass flywheel/drive plate

7 - Dual Mass Flywheel/Drive Plate

❑ Dual Mass Flywheel, removing and installing. Refer to
⇒ “2.2 Dual Mass Flywheel, Removing and Installing”, page 63 .
❑ Drive Plate, removing and installing. Refer to ⇒ “2.3 Drive Plate, Removing and Installing”, page 64 .
❑ Drive plate installed position: the »collar« faces the engine
❑ It is possible to install in one position only - the holes are offset -
8 - Alignment Pin n AG. Volkswagen AG do
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❑ Not installed byV ua
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Transmission Side Sealing Flange, Tightening Sequence
ce
le
un
pt
an
d
itte
– Tighten the bolts -1 through 8- in the sequence shown:
y li
erm
ab
– 1. Tighten the bolts hand-tight.
ility
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wit
is n
– 2. Tighten the bolts to 9 Nm.
h re
ole,
spec
t to the co
rrectness o
cial p
f
Installing the Intermediate Plate
inform
mer
– Hook in intermediate plate at sealing flange and push it onto
atio
the alignment sleeves -arrows-.
om
n
c
i
or
n thi
te
sd
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o
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t.
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Cop py
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gh ht
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co lksw
by
cted agen
Prote AG.
2.2 Dual Mass Flywheel, Removing and In‐

stalling
♦ Flywheel Retainer - 3067-
Removing
– Remove the transmission. Refer to ⇒ Rep. Gr. 37 .
Caution
To prevent damage to the dual-mass flywheel when removing,

bolts -B- must not be removed using an air-powered or impact
wrench. Only removing bolts by hand is permitted.
2. Cylinder Block on Transmission Side 63

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ge, nGolf
AG. V2009
olkswa➤
gen,APassat
G do 2006 ➤ , ...
swa e
4-Cylinder Fuel Injection Engine y(1.8L
Volk and 2.0L Engine, Chains nDrive)
ot g
u
- Edition 07.2015
b ara
ed nte
ris
– Rotate the dual-mass flywheela-A-
ut so that
ho
the bolts -B- stand e or
ac
centered to the holes -arrows-.
ss
ce
le
un
– When removing the bolts -B-, make sure the bolt head does
pt
an
d
itte
not come into contact with the dual-mass flywheel -arrows- or
y li
rm
ab
the flywheel could be damaged when turning the bolt.
pe
ility
ot
– Insert the Flywheel Retainer - 3067- into the hole on the cyl‐
wit
, is n
h re
inder block -B-.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove the dual-mass flywheel.
l purpos
Installing
nform
ercia
Install in reverse order of removal while noting the following:

m
a
com
t
• Tightening specification -item 6- ⇒ Item 6 (page 62) .
ion in
r
te o
– Secure with new bolts.
thi
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Insert the Flywheel Retainer - 3067- into the hole on the cyl‐
inder block -A-.
2.3 Drive Plate, Removing and Installing

♦ Flywheel Lock Adapter - VW558-
♦ Depth Gauge
♦ M8x40 hex bolt and M8 hex nut


Flywheel Lock Adapter - VW558- Preliminary Work:
– Tighten the hex bolt M8x40 -A- with a hex nut on the Flywheel
Lock Adapter - VW558- .
Loosening and Tightening the Drive Plate:
– Insert the Flywheel Lock Adapter - VW558- in the cylinder
block and drive plate as illustrated.
Counterholder installation position: -A- to loosen, -B- to tighten.
Install the Drive Plate: n AG. Volkswagen AG do

lkswage es n
ot g
– First position the drive plate without d bythe
Vo washer -A-. ua
ran
ir se tee
– Insert the used bolts -3- and utighten
tho them to 30 Nm. or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Calculate the dimension between the drive plate and cylinder

block in three locations and calculate the average value.
Note
This is measured through the hole in the drive plate to the ma‐
chined surface of the cylinder block. When measuring on the
intermediate plate, take the thickness
wage
n AG. Vof
olkthe
swagplate
en AG into consider‐
does
ation. y Volks not
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oris e
• Specified value
au measured
th without intermediate plate: 19.5 toor a
21.1 mm ss c
ce
e
nl
pt
• Specified value measured with intermediate plate: 18.8 to 20.4
du
an
itte
mm
y li
erm
ab
ility
If the specified value is reached, replace all bolts and tighten
ot p
wit
them.
, is n
h re
hole
If the specification is not obtained:
spec
es, in part or in w
– Remove the drive plate again and use the shim -A-. Tighten
t to the co
the bolts -3- again to 30 Nm.
– Repeat the measurement. If the specified value is reached,
rrectness of i
replace all bolts and tighten them.
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4 Transmission-Side Sealing Flange, Re‐

moving and Installing
♦ Hand Drill with Plastic Brush Attachment
♦ Protective Eyewear
♦ Silicone Sealant - D 174 003 A2-
♦ Seal Installer - Sealing Flange Guide Sleeve - T20097-
Removing
• The transmission is removed.
• Dual-mass flywheel removed. Refer to
⇒ “2.2 Dual Mass Flywheel, Removing and Installing”,
page 63 or
⇒ “2.3 Drive Plate, Removing and Installing”, page 64 .

– Unhook the intermediate plate at sealing flange and at the

alignment sleeves -arrows-.
– Remove the bolts -1 through 8-
– Remove the transmission side sealing flange.

Installing
Note
♦ Note the expiration date of the silicone sealant.

♦ The sealing flange must be installed within five minutes after
application of silicon sealant.
♦ The sealant bead may not be thicker than specified, otherwise
excess sealant could enter the oil pan and clog the oil intake
pipe screen. en AG. V
olkswagen AG
ag does
lksw not
♦ After installing sealing flange, the sealant bmust
y V dry for approx‐
o gu
ara
imately 30 minutes. Only after then mayris the engine oil be
ed nte
replenished. au
tho eo
ra
ss c
ce
e
– Remove any sealant residue on the cylinder block using a flat

nl
pt
du
an
blade scraper.
itte
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erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
Wear protective eyewear. spec

es, in part or in w
t to the co
– Remove remaining sealant on sealing flange using for exam‐

rrectness of i
ple a rotating plastic brush.

l purpos
– Clean the sealing surfaces. They must be free of oil and

grease.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
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en
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– Cut the tube nozzle at the front marking (nozzle diameter: ap‐
proximately 2 mm).
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– Apply silicone sealant to the clean sealing surface hon risethe seal‐ nte
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♦ Sealant bead thickness: 2 to 3 mm.
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– Position the Seal Installer - Sealing Flange Guide Sleeve -
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T20097- on the crankshaft journal.

– Slide the sealing flange over the Seal Installer - Sealing Flange
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Guide Sleeve - T20097- onto the crankshaft journal.
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– Tighten the bolts -1 through 8- in the sequence shown:
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– 1. Tighten the bolts hand-tight.
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⇒ “3.1 Overview - Crankshaft”, page 69 .
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⇒ “3.2 Sensor Wheel, Removing and Installing”, page 71
spec
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⇒ “3.3 Crankshaft Bearing Shells, Allocating”, page 71
t to the co
⇒ “3.4 Needle Bearings, Removing from Crankshaft and Instal‐
ling”, page 72 .
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⇒ “3.5 Crankshaft Dimensions”, page 74 . l purpos
⇒ “3.6 Crankshaft, Measuring Axial Clearance”, page 74 .
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⇒ “3.7 Crankshaft, Measuring Radial Clearance”, page 75 .
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3.1 Overview - Crankshaft
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Secure engine to assembly stand using Engine and Transmission
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Holder - VAS6095- when performing assembly work. Refer to
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1 - Cylinder Block
❑ If the cylinder block is
being replaced, then the
cylinder block bearing
shells must be allocated
again. Refer to
⇒ “3.3 Crankshaft Bear‐
ing Shells, Allocating”,
page 71 .
2 - Cylinder Block Bearing
Shell
❑ With oil groove
❑ Do not interchange
used bearing shells (la‐
bel)
❑ Labeling the crankshaft
bearing shells. Refer to
page 71 .
3 - Crankshaft
❑ After removal, place in
such a way it does not
rest on the sensor wheel
-5- and damage it
❑ If the crankshaft is being
replaced, then the bear‐
ing shells must be allo‐
cated to the bearing
cap. Refer to
page 71 .
❑ Axial play. Refer to
⇒ “3.6 Crankshaft,
Measuring Axial Clear‐
ance”, page 74
3. Crankshaft 69
❑ Radial clearance. Refer to ⇒ “3.7 Crankshaft, Measuring Radial Clearance”, page 75 .
❑ Do not turn the crankshaft when measuring radial clearance
❑ Crankshaft Dimensions. Refer to ⇒ “3.5 Crankshaft Dimensions”, page 74 .
❑ Removing and installing. Refer to ⇒ “3.2 Sensor Wheel, Removing and Installing”, page 71 .
4 - Bearing Shell
❑ Without oil groove
❑ Do not interchange used bearing shells (label)
❑ Labeling the crankshaft bearing shells. Refer to
⇒ “3.3 Crankshaft Bearing Shells, Allocating”, page 71 .
5 - Bolt
❑ Note the tightening sequence. Refer to ⇒ Fig. ““Crankshaft - Tightening Sequence”“ , page 70 .
❑ Always replace
6 - Bearing Cap
❑ Bearing cap 1: belt pulley side
❑ Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
7 - Bolt
❑ 10 Nm + 1/4 (90°) additional turn
❑ Always replace
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❑ Replace sensor wheel every time bolts are aloosened.
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❑ For Engine Speed Sensor - sG28- s a ac
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❑ Replace sensor wheel every time bolts are loosened

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❑ Removing and installing. Refer to ⇒ “3.2 Sensor Wheel, Removing and Installing”, page 71 .
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9 - Thrust Washers
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❑ For bearing 3 spec

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10 - Bolt
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❑ Note the tightening sequence. Refer to ⇒ Fig. ““Crankshaft - Tightening Sequence”“ , page 70 .
❑ Always replace
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Crankshaft - Tightening Sequence

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– Tighten the crankshaft bolts in -1 to 5- sequence:

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1- Tighten the bolts -1 through 10- and -arrows- by hand.

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2- Tighten the bolts -1 through 10- to 65 Nm.

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3- Tighten the bolts -1 through 10- an additional 90° using a

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4- Tighten the bolts -arrows- to 20 Nm. ht. Cop py
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5- Tighten the bolts -arrows- 90° further using a rigid wrench. py by
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3.2 Sensor Wheel, Removing and Installing

– Remove the engine.
– Remove the crankshaft sealing flange. Refer to
⇒ “2.4 Transmission-Side Sealing Flange, Removing and In‐
– Remove the oil pan upper section. Refer to
⇒ “1.5 Oil Pan Upper Section, Removing and Installing”, pagegen AG. Volkswagen AG
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– Remove the camshaft timing chain and drive chain risfor the bal‐
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ance shaft. Refer to utho eo
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⇒ “1.8 Camshaft Timing Chain, Removing andss Installing”, c
page 111 .
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– Remove the connecting rod bearing cap.
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– Remove the crankshaft bearing cap.
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– Remove the crankshaft and the sensor wheel.
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– Always replace the sensor wheel -2- any time the bolts are
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loosened -1-.
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Note
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♦ After tightening for the second time, the point where the heads
of the countersunk bolts make contact with the sensor wheel
become so deformed that the bolt heads are at the crankshaft
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-3- -arrows- and the sensor wheel lies »loosely« under the
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bolts.
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⇒ “3.1 Overview - Crankshaft”, page 69 .
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3.3 Crankshaft Bearing Shells, Allocating cop Vo
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The bearing shells are allocated to the cylinder block with the
correct thickness at the factory. Colored dots serve to identify the
bearing shell thickness.
The code letters on the lower contact surface or on the top of the
cylinder block identify which bearing shell and where it must be
mounted on the cylinder block (upper bearing shell).
The code letters on the crankshaft identify which bearing shells
and where they must be installed in the bearing cover (lower
bearing shell).
The first letter is for bearing cover one, the second for bearing
cover two, etc.
3. Crankshaft 71
Cylinder Block:
The cylinder block identification may be located either on the oil
pan sealing surface or on the top (transmission side) of the cyl‐
inder block.
The identification on the cylinder block is for the upper bearing
shell (cylinder block bearing shell).
– Note the letters and then match it to the color identification in

the table.
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S = Black
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B = Blue
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W = White
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3.4 Needle Bearings, Removing from

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Crankshaft and Installing

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Only for Vehicles Equipped with a DSG Transmission

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♦ Internal puller, for example Puller - Kukko Internal - 14-19mm

- 21/2-
♦ Bearing Installer - Bearing Press Piece - VW207C-
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• The front ise
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– Remove the needle bearing -1- from the crankshaft -2- using
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– The internal puller must be positioned behind the needle ring
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Installing
– Clean the bearing seat in the crankshaft and apply a thin coat
of grease.
– Drive in the needle bearing with the Bearing Installer - Bearing
Press Piece - VW207C- into the crankshaft to the installation
depth.
3. Crankshaft 73
Installation Depth Dimension -a- = 2.0 mm
Note
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3.5 Crankshaft Dimensions
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Reconditioning Crankshaft Bearing Connecting Rod
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Dimension 1) Pin Diameter Bearing Pin Diame‐
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Standard dimen‐ 58.00 47.80
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♦ Dial Gauge Holder - VW387-

♦ Dial Gauge - 0-10mm - VAS6079-
Procedure
– Attach the Dial Gauge - 0-10mm - VAS6079- with the Dial
Gauge Holder - VW387- to the cylinder block and set with 2
mm pretension against the crankshaft counterweight.
– Press crankshaft by hand against gauge and set gauge to “0”.
– Press crankshaft off the gauge and read the value.
Axial play:
• New: 0.07 to 0.23 mm.
• Wear limit: 0.30 mm.

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3.7 Crankshaft, Measuring Radial Clear‐
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♦ Bearing shells that are worn down to the nickel layer must be
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– Remove main bearing cover and clean the bearing cap and
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pins.
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– Place the Plastigage®over the entire width of the bearing jour‐
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– Position the main bearing cover and tighten it to 60 Nm. Do cted agen
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not rotate the crankshaft when doing so.
– Remove the main bearing cover again.
– Compare the width of the Plastigage® with measuring scale.
Radial clearance:
• New: 0.017 to 0.037 mm.
• Wear limit: 0.15 mm.
3. Crankshaft 75
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⇒ “4.1 Overview - Piston and Connecting Rod”,aut page 76
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⇒ “4.2 Pistons, Removing and Installing”, page 77
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⇒ “4.3 Pistons and Cylinder Bore, Checking”, page 79
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⇒ “4.4 New Connecting Rod, Disconnecting”, page 80
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4.1 Overview - Piston and Connecting Rod
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1 - Connecting Rod Bolt
❑ 45 Nm + 90° additional
turn
rrectne
❑ Always replace
❑ Lubricate the thread and
ss
contact surface.
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❑ Use the old bolt to
form
mer
measure the radial
atio
clearance
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❑ Do not tighten 90° fur‐
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ther when measuring ra‐

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dial clearance.
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2 - Connecting Rod Bearing yi

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❑ Due to the separation
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procedure (cracking) for

the connecting rod, the
cap only fits in one posi‐
tion and only on the cor‐
rect connecting rod.
❑ Mark the cylinder to
which it belongs -A-
❑ Installation position: the
markings -B- face the
belt pulley side
3 - Bearing Shells
❑ Installation position. Re‐
fer to
⇒ Fig. ““Bearing Shell
Installation Position”“ ,
page 77
used bearing shells (la‐
bel)
❑ Axial play new: 0.10 to 0.35 mm, wear limit: 0.40 mm
❑ Measure radial clearance with Plastigage®; new: 0.02 to 0.06 mm, wear limit: 0.09 mm Do not turn
crankshaft when checking radial clearance
4 - Relief Valve
❑ 27 Nm
❑ Opening pressure: 1.6 to 1.9 bar (23.2 to 27.5 psi)
5 - Oil Spray Jet
❑ For piston cooling

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4-Cylinder Engine no (1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015
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6- Circlip rise nte
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7- Piston
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❑ If difficult to move, warm the piston up to approximately 60 ℃

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❑ Remove and install using the Pilot Drift - VW222A-
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8 - Piston
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❑ Removing and installing. Refer to ⇒ “4.2 Pistons, Removing and Installing”, page 77 .
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❑ Checking. Refer to ⇒ page 79 .
spec
es, in part or in w
❑ Mark installed position and cylinder allocation
t to the co
❑ Arrow on piston face points toward belt pulley side
❑ Install with piston ring compressor
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❑ Checking the cylinder bore. Refer to ⇒ page 79 .
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9 - Compression Rings
❑ Offset gaps by 120°
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❑ Use piston ring pliers for removing and installing

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❑ “TOP” or the manufacturer identification must face upward to the piston crown.
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tion in
❑ Checking the ring gap. Refer to ⇒ Fig. ““Checking the Piston Ring Gap”“ , page 79 .
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❑ Checking the piston ring groove clearance. Refer to

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10 - Oil Scraping Ring
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❑ “TOP” or the manufacturer identification must face upward to the piston crown.
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❑ Check the end gap (without hose spring). Refer to ⇒ Fig. ““Checking the Piston Ring Gap”“ , page 79
AG.
❑ Height clearance cannot be measured

11 - Connecting Rod
❑ Always replace as a set
❑ Mark the cylinder to which it belongs -A-
❑ Installation position: the markings -B- face the belt pulley side
Bearing Shell Installation Position

– Place the bearing shells centrally into connecting rod and con‐
necting rod bearing cap.
The dimension -a- must be the same at left and right.
4.2 Pistons, Removing and Installing

♦ Pilot Drift - VW222A-
♦ Commercially Available Piston Ring Compressor
Removing
– Remove the engine. Refer to
⇒ “1.1 Engine, Removing”, page 3 .
4. Piston and Connecting Rod 77

– Separate the engine and the transmission. Refer to

bling”, page 14 .
– Secure the engine to the Engine and Gearbox Bracket -
VAS6095A- . Refer to
– Remove the cylinder head. Refer to
⇒ “2.3 Cylinder Head, Removing and Installing”, page 136 .
– Remove the oil pan upper section. Refer to
⇒ “1.5 Oil Pan Upper Section, Removing and Installing”, page
211 .
– Label the installation position and the cylinder allocation for
the piston.
– Mark installation position and connecting rod cylinder
-item 11- ⇒ Item 11 (page 77) .
– Remove the connecting rod bearing cap and remove the pis‐
ton and connecting rod upward.
Note
Warm the piston to approximately 60 °C (140 °F) if it is difficult to

move the piston pin.
– Remove the circlip from the piston pin eye.

– Remove the piston pin using the Pilot Drift - VW222A- .
Installing wage
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Install in reverse order of removal d while noting the following:
by ua
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• Tightening specifications.au Refer to
th or
ac
⇒ “4.1 Overview - Piston
ss and Connecting Rod”, page 76 .
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♦ Replace the bolts that were tightened with an additional turn.

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♦ Arrow on the piston crown points toward belt pulley side.

spec
es, in part or in w
♦ Piston ring gap offset 120°.

t to the co
– Coat the contact surfaces on the bearing shells with oil.

rrectness of i
– Oil the pistons and the piston rings.

l purpos
– Install the piston with a commercially available piston ring

compressor. Pay attention to the installed position -item 8-
nf
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⇒ Item 8 (page 77) .

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– Install the connecting rod bearing cap. Pay attention to the in‐
atio
m
stalled position -item 2- ⇒ Item 2 (page 76) .

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– Install the cylinder head. Refer to

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– Install the oil pan upper section. Refer to

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4.3 Pistons and Cylinder Bore, Checking

Checking the Piston Ring Gap
– Push ring squarely to the cylinder wall from above down in the
lower cylinder opening approximately 15 mm from bottom
edge of the cylinder. To push in use a piston without rings.
Piston Ring New Wear limit
Dimensions in mm
Compression ring 0.20 to 0.40 0.8
Oil Scraping Ring 0.25 to 0.50 0.8
Piston Ring Groove Clearance, Checking

– Clean the ring groove of piston before checking.
Piston Ring New Wear Limit
Dimensions in mm
1. Compression ring 0.06 to 0.09 0.20
2. Compression ring 0.03 to 0.06 0.15
Oil scraping rings cannot be measured
Pistons, Checking
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♦ Outside Micrometer - 75-100mm - VAS6071- orise nte
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– Measure pistons approximately 10 mm
s from bottom edge and
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at points offset by 90° to piston pin axis.
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♦ Deviations from the specified size: maximum 0.04 mm

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Cylinder Bore, Checking
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The cylinder bore must not be measured when the cylinder block t to the co
is mounted on the Engine and Transmission Holder - VAS6095-
because the measurements may be incorrect.
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♦ Cylinder Dial Bore Gauge - VAS6078-

nform
mer
atio
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Caution
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Do not drill, hone, grind or rework the cylinder bores with work‐
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shop tools. Reworking damages the surface of the cylinder

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4. Piston and Connecting Rod 79

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– Measure diagonally at three positions laterally -A- and au longi‐
th or
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♦ Deviation from specified size: maximum 0.08 mm
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Piston Diameter Cylinder Bore
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• 1) Dimensions without graphite coating (0.02 mm thick). The
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graphite coating wears off.
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4.4 New Connecting Rod, Disconnecting

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New connecting rods might not be completely separated at the

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predetermined breaking point. If the connecting rod bearing cap C py
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by
– Mark which cylinder belongs to the connecting rod -item 11- Prote
cted AG.
agen
⇒ Item 11 (page 77) .
– Lightly clamp the connecting rod in a vise equipped with alu‐
minum protective pads, as shown in the illustration.
Note
♦ Only clamp the connecting rod lightly to avoid damaging it.

♦ Clamp the connecting rod below the dotted line.
– Loosen both bolts -arrows- about five turns.
– Carefully tap against the connecting rod bearing cap in the

direction of -arrow- with a plastic hammer until the cap is loose.

5 Special Tools

equipment required
10-222A-
10-222A/10-
Shackle - 10-222A/12-
♦ Torque Wrench 1331 n AG. Volkswagen AG do
5-50Nm - VAG1331- lkswage es n
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♦ Engine Support Bridge - o
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tee
Gearbox Adapter - auth or
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10-222A/13- ss
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5. Special Tools 81
lkswage es n
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CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009ho➤ r , Passat 2006 ➤ , ...
is tee
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Sub-frame Adapter -
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10-222A/22-
spec
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Engine Support 3 -
rrectness of i
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10-222A/10- quantity: 2
nform
ercia
Shackle - 10-222A/12-
m
at
♦ For automatic transmis‐ om
ion
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Cop py
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♦
10-222A-
10-222A/10- quantity: 2
AG . Volkswagen AG
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Shackle - 10-222A/12-
by
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♦ Engine Support
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Bridge - eo
Engine
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Engine Support Feet -
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10-222A/8-
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nf
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or c
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5. Special Tools 83
♦ Assembly Tool - T10531-
AG. Volkswagen AG d
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♦ Bearing Installer - Bearing Press Piece - VW207C-
lkswage es n
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un
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an
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♦ Pilot Drift - VW222A-
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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tion in
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te o
thi

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t.
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Cop py
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Prote AG.
♦ Flywheel Lock Adapter - VW558-
5. Special Tools 85
AG. Volkswagen AG d
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♦ Puller - Kukko Internal - 14-19mm - 21/2-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
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n in
or c
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♦ Puller - Kukko Counterstay - 22/1-

iv
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♦ Wrench - Pin Type - 3067-
♦ Not Illustrated:
♦ Outside Micrometer - 75-100mm - VAS6071-
♦ Cylinder Dial Bore Gauge - VAS6078-
♦ Counterhold Tool - T10531/1-
♦ Tensioning Pins - T10531/2-

♦ Turning Over Tool - T10531/3-

♦ Knurled Nut - T10531/4-
♦ Seal Installer - Sealing Flange Guide Sleeve - T20097-
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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pt
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ility
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ion
c
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ate
do
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cum
for
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t.
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Cop py
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by c lksw
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Prote AG.
5. Special Tools 87
15 – Cylinder Head, Valvetrain

1 Chain Drive
⇒ “1.1 Overview - Timing Chain Covers”, page 88 .
⇒ “1.2 Camshaft Adjustment Valve 1 N205 , Removing and In‐
⇒ “1.3 Upper Timing Chain Cover, Removing and Installing”, page
91 .
⇒ “1.4 Lower Timing Chain Cover, Removing and Installing, Pas‐
sat and CC”, page 93 .
⇒ “1.5 Lower Timing Chain Cover, Removing and Installing, Rab‐
bit and Eos ”, page 98 .
⇒ “1.6 Lower Timing Chain Cover, Removing and Installing, Ti‐
guan”, page 103 .
⇒ “1.7 Overview - Camshaft Timing Chain”, page 109 .
⇒ “1.8 Camshaft Timing Chain, Removing and Installing”,
page 111 .
⇒ “1.9 Overview - Balance Shaft Drive Chain”, page 123 .
⇒ “1.10 Balance Shaft Drive Chain, Removing and Installing”,
page 125 .
⇒ “1.11 Balance Shaft Intake Side, Removing and Installing”,
gen AG
. Volkswagen AG
does
swa
page 125 . yV
olk not
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ed nte
⇒ “1.12 Exhaust Side Balance Shaft, Removing
tho
ris and Installing”, e or
page 128 . s au ac
s ce
le
⇒ “1.13 Valve Timing, Checking”, page 130 .

un
pt
an
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itte
1.1 Overview - Timing Chain Covers

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Prote AG.
88 Rep. Gr.15 - Cylinder Head, Valvetrain

1 - O-Ring
❑ Always replace
❑ Coat with oil before as‐
sembly
2 - Oil Dipstick Tube
3 - Bolt
AG. Volkswagen AG d
❑ 9 Nm agen oes
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4 - Bolt rised
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❑ a 9 Nm
ut ra
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5 - Camshaft Adjustment Valve
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1 - N205-
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ling. Refer to
ility
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⇒ “1.2 Camshaft Adjust‐
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ment Valve 1 N205 , Re‐
hole
moving and Installing”,
spec
page 91 .
es, in part or in w
t to the co
6 - Seal
❑ Coat with oil before as‐
rrectness of i
sembly
❑ Replace if damaged
l purpos
❑ To replace, remove the

cover
nform
ercia
7 - Bolt
m
at
om
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n
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Refer to
o
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e
⇒ “1.3 Upper Timing

at
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Chain Cover, Removing

p
cum
or
and Installing”,
f
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ng
t.
page 91
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Cop py
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8 - Upper Timing Chain Cover
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cted agen
ling. Refer to ⇒ “1.3 Upper Timing Chain Cover, Removing and Installing”, page 91 .
Prote AG.
❑ Tightening sequence. Refer to

⇒ Fig. ““Upper Timing Chain Cover - Tightening Sequence”“ , page 90
9 - Seal
10 - O-Ring
❑ Always replace
❑ Coat with oil before assembly
11 - Alignment Pins
❑ Centering the cover
12 - Lower Timing Chain Cover
❑ Tightening sequence with 15 bolts. Refer to
⇒ Fig. ““Lower Timing Chain Cover - Tightening Sequence for 15 Bolts”“ , page 90
❑ Removing and Installing
Passat and CC. Refer to
⇒ “1.4 Lower Timing Chain Cover, Removing and Installing, Passat and CC”, page 93 .
Golf, Eos, Scirocco. Refer to

⇒ “1.5 Lower Timing Chain Cover, Removing and Installing, Rabbit and Eos ”, page 98 .
1. Chain Drive 89
Tiguan. Refer to ⇒ “1.6 Lower Timing Chain Cover, Removing and Installing, Tiguan”, page 103 .
13 - Bolt
❑ Always replace
14 - Shaft Seal
❑ For the vibration damper
❑ Always replace. Refer to ⇒ “1.8 Vibration Damper Shaft Seal, Always Replace”, page 59 .
15 - Plugs
❑ Always replace
Upper Timing Chain Cover - Tightening Sequence

– Tighten the bolts -1 through 5- in two stages in the sequence
shown: en AG. V
olkswagen AG
ag does
ksw not
1- Tighten Bolts Hand-Tight y Vol gu
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2- Tighten the Bolts to 9 Nm uthor eo
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Lower Timing Chain Cover - Tightening Sequence for 15 Bolts
es, in part or in w
t to the co
shown:
rrectness of i
– 2. Turn the bolts an additional 45°.

l purpos
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om
ion
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ate
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for
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ng
t.
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Cop py
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Vo
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by
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Prote AG.

Lower Timing Chain Cover - Tightening Sequence for 8 Bolts

shown:
– 2. Turn the bolts an additional 45°.
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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pt
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ility
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es, in part or in w
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1.2 Camshaft Adjustment Valve 1 - N205- ,
Removing and Installing
rrectness of i
ped. Refer to
l purpos

nform
ercia
– Disconnect the connector from the Camshaft Adjustment

m
at
Valve 1 - N205- -1-.
om
ion
c
in t
r
– Remove the bolts -arrows- and then the Camshaft Adjustment

o
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e
Valve 1 - N205- .
at
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Installing
for
en
ng
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• Tightening specification. Refer to Cop py
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Install in reverse order of removal and note the following: by c lksw
cted agen
Prote AG.
– Coat the sealing ring and the O-ring with engine oil.
1.3 Upper Timing Chain Cover, Removing

and Installing
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
♦ Torque Wrench 1783 - Open Jaw - 10mm - VAG1783/1-
Removing
1. Chain Drive 91
– Vehicles with sound generator: open the locking mechanism

-1-, unclip the fuel lines -2- and loosen the bolt -3- on the EVAP
canister. Move the charge air pipe aside.
Vehicles with an EVAP Canister inside the Engine Compartment:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
s c
– Disconnect the vent line -1-, unlock the EVAP canister in di‐ s
ce
e
rection of -arrow A- and remove it upward in direction of

nl
pt
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an
-arrow B-. Move the EVAP canister to the side.
itte
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ab
All:
ility
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es, in part or in w
t to the co
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– Remove the coolant pipe bolts -arrows- from the intake mani‐
fold.
nform
ercia
– Press the coolant hoses to the side and secure them to the
m
at
om
engine mount with a cable tie.
ion
c
in t
or
– Remove the Camshaft Adjustment Valve 1 - N205- .
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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cted agen
Prote AG.
– Remove the bolts -1 through 5- and remove the upper timing

chain cover.
Note
Remove the lower bolts -3 and 5- with an open end wrench.
Installing:
– Coat the seal and the O-ring with engine oil.
– Place the cover on the engine while making sure the seal is
seated correctly.

– Tighten the bolts -1 through 5- evenly by hand in the illustrated

sequence.
– Tighten the bolts to 9 Nm. Use the Torque Wrench 1783 -
2-10Nm - VAG1783- and the Torque Wrench 1783 - Open Jaw
- 10mm - VAG1783/1- for the bolts -3- and -5-.
– Install the Camshaft Adjustment Valve 1 - N205- . Refer to
⇒ “1.2 Camshaft Adjustment Valve 1 N205 , Removing and
lkswage es n
o ot g
byV ua
d ran
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ss
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– Tighten the bolts -arrows- for the guide tube.

un
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itte
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rm
ab
pe
Note
ility
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wit
, is n
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If the attachment point does not line up, check whether the guide
hole
tube is inserted all the way into the lower timing chain cover.
spec
es, in part or in w
t to the co
• Tightening specifications. Refer to
rrectness of i
l purpos
1.4 Lower Timing Chain Cover, Removing nform

ercia
and Installing, Passat and CC

m
a
com
tion in

r
te o
thi
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fo

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ng
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op
♦ Bits for VAG1331/13 - T10099- C py
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cted agen
♦ Passat from MY 2006: Engine Support Bridge - Engine Brack‐
Prote AG.
et - 10-222A/1-
♦ CC: Engine Support Bridge - Engine Support Feet - 10-222A/
8-
Removing
– Drain the engine oil.
– Hold the engine in its installation position.
1. Chain Drive 93
Passat from MY 2006:

Volkswa
♦ Engine Support Bridge - EngineswBracket
agen
AG.- 10-222A/1-
gen AG
does
olk not
V gu
♦ Engine Support - Bracket by
dw/Spindle and Hook - 10-222A/10- ara
ise nte
or eo
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aut Shackle (2 pc.) - 10-222A/12- ra
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spec
es, in part or in w
t to the co
CC:
rrectness of i
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nform
ercia
Note
m
a
com
tio
♦ The Engine Support Bridge - Engine Support Feet - 10-222A/
n in
r
te o
8- must not be placed on the fender bolting plates or they could
thi
s
get damaged.
iva
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fo

en
ng
t.
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op
C py
ht. rig
rig ht
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by lksw
All: Prote
cted AG.
agen

– Remove the engine mount. Refer to
CC”, page 19 .
– Lift the engine approximately 50 mm and loosen the upper bolt
for the engine support.
– Now lower the engine approximately 100 mm.
– Remove the lower engine support bolts using the Bits for
VAG1331/13 - T10099- .
– Remove the engine support and the bolts.

– Remove the bolts -arrows- and remove the oil dipstick tube
from the timing chain cover.
– Disconnect the Wastegate Bypass Regulator Valve - N75-
from the turbocharger -arrows-.
– Remove the turbocharger support -1-.
– Remove the bolts -1 through 15-.
Note
There may be only 8 bolts installed, depending on the version.

AG. Volkswagen AG d
agen oes
olksw not
V gu
Caution d by ara
ise nte
or eo
h
ut ra
There is a risk of damaging the lower timing
ss a
chain cover. To c
avoid deformation, do not hold between the bolting points.
ce
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erm
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ility
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hole
spec
es, in part or in w
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nf
ercia
orm
m
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om
n in
or c
thi
te
sd
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Cop py
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by c lksw
cted agen
Prote AG.
1. Chain Drive 95
– Pry off the lower timing chain cover; when doing this, begin at
-1 and 2-.
Installing
♦ Sealant: Silicone Sealant - D 174 003 A2-
Note
♦ If the cover was bent while it was being removed, it must be

replaced. n AG. Volkswagen AG do
lkswage es n
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♦ Note the expiration d b date
yV of the silicone sealant. ua
ran
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♦ The cover amust
utho
be installed within five minutes after applying or
the silicone
ss sealant.
ac
ce
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nl
♦ Replace the bolts that are being tightened with an additional
pt
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ab
♦ Replace sealing rings, seals and self-locking nuts.
ility
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spec
Caution
es, in part or in w
♦ Risk of contaminating the lubricating system. Cover open t to the co

parts of the engine. rrectness of i
♦ Wear protective eyewear.

l purpos

nform
ercia
blade scraper.
m
at
– Seal off both side of the seal with tape to prevent contamina‐
om
io
tion.
n
c
in t
or
his
e
– Use a rotating plastic brush to remove any sealant residue

at
do
riv
from the cover.

p
cum
for
en
ng
t.
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– Clean the sealing surfaces. They must be free of oil and Cop py
grease.
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Checking the Cover for Distortion:
c by lksw
cted agen
Prote AG.
– Install the cover using the old bolts and tighten to 8 Nm.
– Check between the cover and housing using a feel gauge; the
gap must not exceed 0.2 mm.
Note
♦ If the gap exceeds 0.2 mm, replace the cover.

♦ It is not possible to measure between the cover the upper sec‐
tion of the oil pan, however check the sealing surface for
evenness.

. Volkswage
CC 2010 w➤ , nEos
age
AG
2006 ➤ n, AGolf
G do 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
es n
olks o g
4-Cylinder Fuel
d by Injection Engine (1.8L and 2.0Lt Engine,
V ua
r
Chain Drive) - Edition 07.2015
e an
ris tee
ho
Installing the Cover:s au
t or
ac
s
– If necessary, remove the Assembly Tool - Knurled Nut -
ce
le
un
pt
T10531/4- and remove the Turning Over Tool - T10531/3- .
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Make sure both alignment bushings for centering the cover

-arrows- are present.
nform
mercia
a
com
tion in
r
te o
thi
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cum
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Cop py
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Prote AG.
proximately 2 mm).
Cover with 15 Bolts

– Apply the Silicone Sealant - D 174 003 A2- to the clean sealing
surface -arrow 1- and on the edges -arrows 2- of the new cover
as shown in the illustration.
1. Chain Drive 97
Cover with 8 Bolts

lkswage es n
o ot g
Note byV ua
d ran
ir se tee
tho
or
♦ The cover must be installed within five sminutes after applica‐
au ac
s
tion of silicone sealant.
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e
nl
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erm
ab
pipe screen.
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, is n
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– Immediately attach the cover and tighten the bolts:
hole
spec
es, in part or in w
♦ Cover with 15 bolts. Refer to
t to the co
⇒ Fig. ““Lower Timing Chain Cover - Tightening Sequence for
15 Bolts”“ , page 90
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
Note
iv
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cu
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f
en
ng
After installing cover, allow sealant to dry for approximately 30

t.
yi Co
minutes. Only after then may the engine oil be replenished. Cop py
t. rig
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o
– Fill the engine oil and check the oil level.
c by lksw
cted agen
Prote AG.
1.5 Lower Timing Chain Cover, Removing

and Installing, Rabbit and Eos
♦ Bits for V.A.G. 1331/13 - T10099-
♦ Golf: Engine Support Bridge - Gearbox Adapter - 10-222A/13-
♦ Eos, Scirocco: Engine Support Bridge - Engine Bracket -
10-222A/1-
Removing

Vehicles with Sound Generator:

– Remove the charge air guide leading to the sound generator.
Refer to
All:
lowing tool parts:
Golf:
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/13-
(quantity: 2)
lkswage es n
Eos and Scirocco: byV
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ua
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an
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erm
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ility
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Note
wit
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hole
spec
es, in part or in w
t to the co
could get damaged.
rrectness of i
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All:
nform
ercia

m
at
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ion

c
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te

a
do
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p
cum
or
CC”, page 19 .
f
en
ng
t.
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op
– Lift the engine approximately 50 mm and loosen the upper bolt C py
t. rig
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by
– Now lower the engine approximately 100 mm. cted agen
Prote AG.
1. Chain Drive 99

V.A.G. 1331/13 - T10099- .
lkswage es n
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du
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
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c
Note
or
thi
te
sd
iva

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cu
o
m
f
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t.
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Cop py
Caution
t. rig
gh ht
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by
There is a risk of damaging the lower timing chain cover. To cted agen
Prote AG.

-1 and 2-.
Installing:
♦ Sealant: Silicone Sealant - D 174 003 A3-
Note

replaced.
♦ The cover must be installed within five minutes after applying
the silicone sealant.
turn.
Caution agen
AG. Volkswagen AG d
oes
olksw not
V gu
by
♦ Risk of contaminating the lubricating
rised system. Cover open ara
nte
parts of the engine. ut
ho eo
ra
s a c
♦ Wear protective eyewear. s
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
blade scraper.
wit
, is n
h re
hole
tion.
spec
es, in part or in w
– Use a rotating plastic brush to remove any sealant residue t to the co

from the cover.
rrectness of i

grease.
l purpos

nf
ercia
orm
m
atio
om

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or c
thi
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Note
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♦ If the gap exceeds 0.2 mm, replace the cover. Cop py
t. rig
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p by
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by c lksw
tion of the oil pan, however check the sealing surface for Prote
cted AG.
agen
evenness.
1. Chain Drive 101

Installing the Cover:

– If necessary, remove the Vibration Damper Assembly Tool -
Knurled Nut - T10531/4- and remove the Vibration Damper
Assembly Tool - Turning Over Tool - T10531/3- .

proximately 2 mm).
AG. Volkswagen AG d
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Cover with 15 Bolts

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
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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cted agen
Prote AG.

Cover with 8 Bolts

– Apply the SiliconewSealant
agen
AG. V-oD 174 003 A2-
lkswagen AG
doesto the clean sealing
s
surface -arrow y V 1- and on the edges -arrows 2-t of
olk no
gu the new cover
as shownir se in the illustration.
d b ara
nt ee
tho or
♦ Sealant
sa
u bead thickness: 2 to 3 mm. ac
s
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
♦ The cover must be installed within five minutes after applica‐
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
pipe screen.
rrectness of i
l purpos

nform
ercia

m
at
om
io
n
c
in t
or
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e

at
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riv

p
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ng
t.
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Cop py
t. rig
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yri by
Note
cop Vo
by lksw
cted agen
Prote AG.
minutes. Only after then may the engine oil be replenished.
– Fill the engine oil and check the oil level.
1.6 Lower Timing Chain Cover, Removing

and Installing, Tiguan
tity: 2)
(quantity: 2)
♦ Bits for VAG1331/13 - T10099-
1. Chain Drive 103

Removing
page 465 .
Caution

the battery.

. Volkswagen AG
-arrow- on the battery. swa
gen AG does
k not
Vol gu
– Remove the battery. Refer to ⇒ Rep. Gr. 27 ; Battery,
db
y
Re‐ ara
ise nte
moving and Installing; Battery, Removing andthoInstalling .
r eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.


shown.
lkswage es n
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tho
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un
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d
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rm
ab
lowing tool parts:
pe
ility
ot
wit
, is n
(quantity: 2)
h re
hole
spec
es, in part or in w
tity: 2)
t to the co
(quantity: 2)
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r

te o
thi
s
lowing tool parts:

iva
do
r
rp
cum
fo
en
ng
t.
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op
C py
t. rig
gh
(quantity: 2)
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
tity: 2)
(quantity: 2)
All:
1. Chain Drive 105


CC”, page 19 .
– Lift the engine approximately 50 mm and loosen the upper bolt
AG . Volkswage
– Now lower the engine approximately
ksw
agen 100 mm.
n AG d
oes
n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
V.A.G. 1331/13 - T10099- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
m
a
com

ion in
r
te o

thi
s
iva

do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.

– Remove the bolts -1 through 15-. n AG. Volkswagen AG do

lkswage es n
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Note ir se tee
tho
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du
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itte
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erm
ab
Caution
ility
ot p
wit
, is n
There is a risk of damaging the lower timing chain cover. To
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
-1 and 2-.
o
n in
or c
Installing:
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
♦ Sealant: Silicone Sealant - D 174 003 A3- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.

replaced.
turn.
Caution
♦ Risk of contaminating the lubricating system. Cover open

parts of the engine.

blade scraper.
tion.
1. Chain Drive 107

wage Engine (1.8L and
n AG. Volkswagen AG do 2.0L Engine, Chain Drive) - Edition 07.2015
e
ks s no
Vol t gu
by ara
– Use a rotating plastic
ris
ed
brush to remove any sealant residue nte
from the cover.
autho eo
ra
ss c
ce
e
nl
grease.
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
Note
rrectness of i
♦ If the gap exceeds 0.2 mm, replace the cover.
l purpos

tion of the oil pan, however check the sealing surface for
nform
ercia
evenness.
m
at
om
ion
c
Installing the Cover:
in t
or
his
ate
– If necessary, remove the Assembly Tool - Knurled Nut -
do
priv
c
T10531/4- and remove the Assembly Tool - Turning Over Tool
um
for
- T10531/3- .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

proximately 2 mm).

Cover with 15 Bolts

Cover with 8 Bolts
Note
♦ The cover must be installed within five minutes after applica‐

♦ The sealant bead may not be thicker than specified, otherwise AG. Volkswagen AG d
excess sealant could enter the oil pan and clog the oil intakeolkswagen oes
not
pipe screen. db
yV gu
ara
e nte
ris
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c
ss
ce
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nl
pt
du
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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
Note
nf
ercia
o
rm
m
minutes. Only after then may the engine oil be replenished.
atio
om
n in
or c
– Fill the engine oil and check the oil level. thi
te
sd
iva
o
r
rp
cu
o
1.7 Overview - Camshaft Timing Chain

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Chain Drive 109

1 - Bolt
❑ 9 Nm
2 - Chain Tensioner
❑ Is under tension
❑ Depending on the ver‐
sion, secure with either
the Locking Pin (3 pc.) -
T40011- or the Tension‐
er Locking Tool -
T40267- .
3 - Timing Chain Tensioning
Rail
4 - Guide Pin
❑ 20 Nm n AG. Volkswagen AG do
lkswage es n
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5 - Bolt d byV ua
ran
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❑ 9 Nm utho tee
or
a ac
6 - Regulator Valve ss
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e
nl
pt
❑ 35 Nm
du
an
itte
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❑ Left-hand thread
erm
ab
ility
❑ Removing using Central
ot p
wit
Valve Assembly Tool -
, is n
h re
T10352-
hole
spec
❑ Engine Codes CCZA,
es, in part or in w
CCZB, CCZC, CCZD,
t to the co
CDAA, CDAB: Remove
with Central Valve As‐
sembly Tool - T10352/1-
rrectness of i
7 - Bolt
l purpos
❑ M6: 8 Nm + 90° addi‐

tional turn nform
ercia
❑ M8: 20 Nm + 90° addi‐

m
tional turn
at
om
ion
❑ Always replace
c
in t
or
his
te
8 - Washer
a
do
priv
cum
or
9 - Bearing Bracket
f
en
ng
t.
yi Co
10 - Camshaft Timing Chain Guide Rail Cop py
t. rig
gh ht
yri
11 - Camshaft Housing p by
co Vo
by lksw
cted agen
12 - Camshaft Timing Chain Prote AG.
❑ Before removing, mark the running direction with paint

❑ Removing and installing. Refer to ⇒ “1.8 Camshaft Timing Chain, Removing and Installing”, page 111 .
13 - Camshaft Timing Chain Guide Rail
14 - Guide Pin
❑ 20 Nm
15 - Chain Sprocket
❑ Crankshaft
❑ Installation position. Refer to ⇒ Fig. ““Chain Sprocket Crankshaft, Installation Position”“ , page 111

CCag2010
en AG.➤
Vol,ksEos
wage2006
n AG d ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
oes
sw
4-Cylindery VolkFuel Injection Engine (1.8L noand
t gu 2.0L Engine, Chain Drive) - Edition 07.2015
d b ara
ise nte
r
Chain Sprocket
aut Crankshaft, Installation Position
ho eo
ra
ss c
• Both surfaces -arrows- must align across from each other.
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
1.8 Camshaft Timing Chain, Removing and

Installing
nform
ercia

m
at
om
io
♦ Central Valve Assembly Tool - T10352-
n
c
in t
or
his
e

at
do
priv
c
♦ Locking Pin (3 pc.) - T40011-
um
for
en
ng
t.
yi
♦ Chain Tensioner Lever - T40243-
Co
Cop py
ht. rig
♦ Tensioner Locking Tool - T40267- rig ht
py by
co Vo
by lksw
♦ Camshaft Locks - T40271- cted agen
Prote AG.

♦ Vibration Damper Assembly Tool - Counterhold Tool -
T10531/1-
♦ Vibration Damper Assembly Tool - Tensioning Pins -
T10531/2-
♦ Vibration Damper Assembly Tool - Turning Over Tool -
T10531/3-
Removing:
– Remove the upper timing chain cover. Refer to
⇒ “1.3 Upper Timing Chain Cover, Removing and Installing”,
page 91 .
1. Chain Drive 111


• The markings -1- on the camshafts must point upward.
– Remove the lower timing chain cover:
⇒ “1.4 Lower Timing Chain Cover, Removing and Installing,
Passat and CC”, page 93 .
Rabbit and Eos ”, page 98 .
Tiguan. Refer to
Tiguan”, page 103 .
– Remove the control valve in direction of -arrow- using the

Central Valve Assembly Tool - T10352-
Caution
The control valve has left-hand thread.
– Remove the bolts -arrows- and remove gthe

en Abearing
G. Volkswabracket.
gen AG
d wa oes
olks not
– Press the oil pump chain tensioner
db
y V in the direction of -arrow- gu
ara
and secure it with a LockingoriPin
se (3 pc.) - T40011- . nte
eo
th
s au ra
c
s
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
– Remove the drive chain tensioner -1-.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
112
agen
Prote AG.
Rep. Gr.15 - Cylinder Head, Valvetrain

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2 Different Chain Tensioners May Be Installed Depending on the
Version, Version 1:
rrectness of i
– Install the Chain Tensioner Lever - T40243- -arrows-.
l purpos
– Lift up the locking wedge for the chain tensioner -arrow 1-.
Sand the end of the Locking Pin (3 pc.) - T40011- down to a
point. A screwdriver with a blade width of approximately 1.5
nform
ercia
mm can also be used.

m
a
com
tion in
Caution
r
te o
thi
s
iva
do
There is a risk of damaging the chain tensioner. Proceed very
r
rp
cum
carefully.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
– Slowly press and hold the Chain Tensioner Lever - T40243- yri
p by
o Vo
in the direction of -arrow 2-.
c by lksw
cted agen
Prote AG.
– Secure the chain tensioner using the Locking Pin (3 pc.) -

T40011- .
1. Chain Drive 113

Version 2: n AG. Volkswagen AG do

lkswage es n
– Install the Chain Tensioner Lever - T40243- -arrows-.byV
o ot g
ua
d ran
ir se
– Press the chain tensioner circlip -1- together
utho and hold it. tee
or
s a ac
– Slowly press and hold the Chain Tensioner Lever - T40243-
s
ce
e
in the direction of -arrow-.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Secure the chain tensioner with the Tensioner Locking Tool -

m
at
T40267- .
om
ion
c
in t
r
All
o
his
ate
do
riv
– Remove the Chain Tensioner Lever - T40243- .

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Bolt the Camshaft Locks - Component 2 - T40271/2- to the

cylinder head and into the splines on the chain sprocket in the
direction of the arrow -2-. If necessary, turn the intake cam‐
shaft slightly with a wrench -1-.

– Install the Camshaft Lock - Component 1 - T40271/1- on the

cylinder head. Hold the camshaft with a wrench in a clockwise
direction -arrow-.
– Remove the bolt -A- and Aremove the
G. Volkswagentensioning
AG do
rail while con‐
tinuing to hold the w agen
camshaft. es n
olks o t gu
yV
db ara
rise nte
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ss
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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
– Slide the Camshaft Lock - Component 1 - T40271/1- into the

chain sprocket splines -2-. If necessary, turn the exhaust cam‐
shaft -1- farther clockwise, until the camshaft locating tool can
nf
ercia
be pushed in. The camshaft timing chain must be »loose« be‐
orm
tween the chain sprockets.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
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.
– Remove the bolts -A- and then remove the camshaft timing
chain glide rail.
1. Chain Drive 115

– Remove the camshaft timing chain from the camshaft sprock‐

ets and hang it on the camshaft pins -arrows-.
– Remove the chain tensioner -1- for the drive chain balance
shaft.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
– Remove the bolts -1-. Remove the tensioning rail -2- and the
h re
hole
glide rails -3 and 4-.
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
e
– Loosen the adjusting bolt -A- and remove the tensioning pin
t
sd
iva
-B-.
o
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rp
cu
o
m
f
– Remove the three stage chain sprocket by removing the drive

en
ng
t.
yi Co
chain for the oil pump. . Cop py
rig
ht ht
rig
– Remove the camshaft timing chain. py by
co Vo
by lksw
cted agen
Prote AG.

Installing
– Check that the crankshaft is at TDC. The flat area on the
crankshaft -arrow- must be horizontal.
– Draw the markings on the cylinder block -1-, as shown, with a
waterproof marker.
– Draw a marking -2- on the three stage chain sprocket tooth

-1- with a waterproof marker.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Turn the intermediate sprocket and uthobalance shaft to the mark‐ eo
ra
ings -arrow-, do not loosen the sbolt
s a -1-. The markings on the c
intermediate sprocket and the balance shaft are difficult to see
ce
e
nl
pt
and align only every 7th turn.
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
– Lay the balance shaft drive chain, and position the painted
l purpos
links -arrows- on the chain sprocket markings.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Chain Drive 117

– Install the guide rail -1- and tighten the bolts -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Engage the camshaft timing chain with the painted links
nl
pt
du
-arrows- on the camshaft pins.
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
– Lay the oil pump drive chain on the three-stage chain sprocket.
nform
ercia
– Tilt the three stage chain sprocket in the direction of -arrow-

m
at
om
toward the engine and secure it to the crankshaft. The marking
ion
c
-arrows- must be positioned opposite each other.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

I - Install the Vibration Damper Assembly Tool - Tensioning Pins

- T10531/2- in the crankshaft and tighten hand-tight.
II - Install the Vibration Damper Assembly Tool - Turning Over
Tool - T10531/3- . Tighten the Vibration Damper Assembly Tool
- Knurled Nut - T10531/4- hand-tight. Using a 32 mm open end
wrench move the Vibration Damper Assembly Tool - Turning Over
Tool - T10531/3- back and forth slightly while doing this tighten
the Vibration Damper Assembly Tool - Knurled Nut - T10531/4-
until the chain sprocket is seated securely on the crankshaft
splines. Now tighten the adjusting bolt -A-.
– Position the painted chain link in the balance shaft drive chain
-arrow- at the marking on the three stage chain sprocket. In‐
stall the tensioning rail -1- and the glide rail -2-. Tighten the
bolts -3-.
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– Install the chain tensioner -1-.
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– Check the adjustment again. The painted chain links

-arrows- must line up with the markings on the chain sprock‐
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1. Chain Drive 119

– Place the camshaft timing chain on the intake camshaft, ex‐

haust camshaft and the crankshaft. Position the painted chain
links -arrows- on the markings on the chain sprockets.
AG. Volkswagen
– Install the camshaft timinglkchain
wage guide rail and tighten
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not bolts
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Use the help of a second technician to hold the exhaust camshaft

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– Slowly turn the exhaust camshaft in the direction of the arrow

h re
-1- until the Camshaft Locks - component 1 - T40271/1- can

hole
spec
be pulled from the chain sprocket splines.

es, in part or in w
t to the co
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atio
– Carefully release the camshaft, until the camshaft timing chain

om
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is laying on the upper guide rail. Hold the camshaft in this po‐
or c
sition.
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Caution
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Always check before installing the tensioning rail, whether the ht. rig
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colored chain link is still aligned to the markings on the cam‐
py by
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agen
– Continue to hold the camshaft and install the camshaft timing

chain tensioning rail. Tighten the bolt -A-.

– Remove the Camshaft Locks - Component 1 - T40271/1- .

– Slide the Camshaft Locks - Component 2 - T40271/2- out of
the chain sprocket splines -2-. If necessary, slightly turn the
intake camshaft with the wrench -1-.
AG. Volkswagen AG d
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– Remove the Camshaft Lockau-t Component 2 - T40271/2- .
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ate
– Depending on the version, remove either the Locking Pin (3

do
priv
pc.) - T40011- or the Tensioner Locking Tool - T40267- .

um
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1. Chain Drive 121

– Check that the position of the colored chain link is aligned to

the markings.
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rrectness of i
– Install the chain tensioner -2-. The wire clip -arrow- must come
in to contact with the oil pan upper section opening. Tighten
l purpos
the bolt -1- and remove the Locking Pin (3 pc.) - T40011- .
nform
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– Install the bolts -arrows- and tighten them. Prote
cted AG.
agen
– Carefully attach the bearing mount, without tilting. Hand-tight‐

en the bolts -arrows-.
– Tighten the bolts -arrows-. Refer to
– Install the control valve -item 6- ⇒ Item 6 (page 110) .

– Turn the crankshaft with a SW 32 open end wrench on the

Vibration Damper Assembly Tool - Turning Over Tool -
T10531/3- two times in the direction of engine rotation. In the
“TDC point” the flat area -1- points upward.
Note
Due to the ratio, the painted chain links no longer match up after
the engine has been turned.
1.9 Overview - Balance Shaft Drive Chain
1 - Bolt
❑ 9 Nm
2 - Balance Shaft
❑ Replace after removing
❑ Exhaust side
❑ Lubricate the bearing
with engine oil
❑ Removing. Refer to
⇒ “1.12 Exhaust Side
Balance Shaft, Remov‐
ing and Installing”, page
128 .
3 - Pipe for the Balance Shaft
❑ Installation position. Re‐
fer to
⇒ Fig. ““Balance Shaft AG. Volkswagen AG d
Pipe - Installed Posi‐ olksw
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4 - Chain Tensioner utho or
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❑ 85 Nm ss
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5 - Cylinder Block
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6 - Balance Shaft
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❑ Replace after removing

ot
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❑ Intake side
hole
spec
❑ Lubricate the bearing

es, in part or in w
with engine oil

t to the co
❑ Removing. Refer to
⇒ “1.11 Balance Shaft
rrectness of i
Intake Side, Removing

and Installing”,
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page 125 .
7 - O-Ring
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❑ Lubricate with engine oil

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8 - Mounting Pin
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❑ Installation position. Refer to ⇒ Fig. ““Mounting Pins - Installation Position”“ , page 124
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9 - Intermediate Shaft Sprocket

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❑ For the balance shaft Cop py
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❑ The intermediate shaft sprocket must be replaced if the bolt is loosened.
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1. Chain Drive 123

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4-Cylinder Fuel Injection Engine o(1.8L
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10 - Bolt ss
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❑ 9 Nm
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11 - Washer
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12 - Bolt
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❑ The intermediate shaft sprocket must be replaced if the bolt is loosened.
hole
spec
❑ Tightening sequence. Refer to ⇒ Fig. ““Chain Sprocket, Tightening Sequence”“ , page 125
es, in part or in w
t to the co
13 - Guide Rail
❑ for the drive chain
rrectness of i
14 - Guide Pin
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❑ 20 Nm
15 - Tensioning Rail
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16 - Guide Pin
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❑ 20 Nm
or
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17 - Balance Shaft Drive Chain
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❑ Removing and installing. Refer to
f
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⇒ “1.10 Balance Shaft Drive Chain, Removing and Installing”, page 125 .
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18 - Chain Sprocket
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❑ Installation position. Refer to ⇒ Fig. ““Chain Sprocket Crankshaft, Installation Position”“ , page 111
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19 - Guide Rail
20 - Guide Pin
❑ 20 Nm
Balance Shaft Pipe - Installed Position

• The pin from the balance shaft pipe must fit into the groove
-arrow-
Mounting Pins - Installation Position

• Replace and lubricate the O-ring -1-
• The alignment pin -arrow- for the bearing pins must engage in
the hole in the cylinder block.
• Lubricate the mounting pins

Chain Sprocket, Tightening Sequence wagen AG. Volkswagen AG does

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Caution tho
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Always replace the intermediate shaft sprocket. Otherwise the
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backlash will not adjust itself and it could result in engine dam‐
pt
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age. The new intermediate shaft sprocket has an anti-friction itte
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erm
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coating that wears off after a short period of use, which auto‐
ility
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matically adjusts the backlash.
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t to the co
1. Tighten to 10 Nm using a torque wrench.
2. Turn the chain sprocket.
rrectness of i
The chain sprocket may not have any play; if so, loosen and tight‐
l purpos
en again.
3. Tighten to 30 Nm using a torque wrench.
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4. Turn another 90° using a rigid wrench.
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1.10 Balance Shaft Drive Chain, Removing

or
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and Installing
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The procedure “Balance shaft drive chain removing and installing”
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is in the “Camshaft timing chain removing and installing” proce‐
Co
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⇒ “1.8 Camshaft Timing Chain, Removing and Installing”, py by
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page 111 .
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1.11 Balance Shaft Intake Side, Removing

and Installing
♦ Puller - Balancer Shaft - T10394-
♦ Puller - Unit Injector - T10055-
Note
Always replace the balance shaft after removing it.
Removing:
– Remove the coolant pump toothed belt. Refer to
⇒ “2.3 Coolant Pump Toothed Belt, Removing and Installing”,
page 244 .
page 91 .
Tiguan. Refer to
1. Chain Drive 125

– Remove the camshaft timing chain and drive chain for then Abal‐
wage
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ance shaft. Refer to yV
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⇒ “1.8 Camshaft Timing Chain, Removing and ed b Installing”, ara
nte
ris
page 111 . utho eo
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– Remove the intermediate sprocket -1-.
s
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pt
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itte
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the bolt -2- for the intake camshaft balance shaft and
remove the balance shaft.
nform
ercia
If the Balance Shaft Cannot Be Removed by Hand, Use the Puller

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om
i
- Balancer Shaft - T10394- :
on
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ate
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– Insert the Puller Jaw - T10394/1- from the Puller - Balancer

Shaft - T10394- and turn upward in direction of arrow.
– Insert the Puller - Balancer Shaft - T10394- and push the slid‐
ing sleeve in the direction of -arrow-.

– Install the Puller - Unit Injector - T10055- into the Puller - Bal‐
ancer Shaft - T10394- and remove the balance shaft in the
direction of -arrow-.
Installing
Note
Because of the small clearance between the balance shaft and

cylinder block, the balance shaft may need to be cooled in order
AG. Volkswagen AG d
to install it. Check lkswif the balance shaft can
agen oesbe inserted into the
no
cylinder block by Vwithout forcing it in. If it cannot,t gthe
o
ua balance shaft
must beoricooled before installing it.
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– Place the new balance shaft in a freezer for 30 minutes or
erm
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spray it with commercially available cooling spray.
ility
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– Lubricate the balance shaft bearing with engine oil.
h re
hole
spec
– Install the new intake camshaft balance shaft and tighten the
es, in part or in w
t to the co
bolt -2-.
rrectness of i
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ate
do
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– Replace the O-ring -1- and coat with engine oil.

f
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op
– Coat the bearing pin with engine oil and install it -arrow-. The
C py
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bearing pin must engage in the hole in the cylinder block.
rig ht
py by
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Prote AG.
Caution
Always replace the intermediate shaft sprocket. Otherwise the

backlash will not adjust itself and it could result in engine dam‐
age. The new intermediate shaft sprocket has an anti-friction
coating that wears off after a short period of use, which auto‐
matically adjusts the backlash.
– Mark the tooth flank on the intermediate sprocket -arrows-.

– Install the intermediate sprocket; the marking on the balance
shaft must be between the markings on the tooth faces.
1. Chain Drive 127

– Tighten the screw -1- for the chain sprocket: tightening se‐
quence. Refer to
⇒ Fig. ““Chain Sprocket, Tightening Sequence”“ , page 125 .
– Check the markings on the intermediate shaft sprocket/bal‐
AG. Volkswagen AG d
ance shaft -arrow-. ksw
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Note utho or
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Due to the ratio, the markings align only every 7th turn.
un
pt
an
d
itte
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– Install the drive chain for the balance shaft and the camshaft
ility
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timing chain. Refer to ⇒ page 117 .
wit
is n
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The rest of the assembly is basically a reverse of the removal.
ole,
When at the same time, note the following:
spec
t to the co
– Replace the coolant pump shaft seal. Refer to
⇒ “2.4 Coolant Pump Drive Shaft Seal, Always replace”, page
245 .
rrectne
1.12 Exhaust Side Balance Shaft, Removing
ss
and Installing
o
cial p
f inform
mer
atio
m

o
n
c
i
or
n
thi
te
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pr
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Note
en
ng
t.
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Cop py
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Always replace the balance shaft after removing it.
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Removing:
Prote AG.

page 91 .
Tiguan. Refer to
– Remove the camshaft timing chain and drive chain for the bal‐
ance shaft. Refer to
page 111 .

– Remove the bolt -1- and the balance shaft.

If the Balance Shaft Cannot Be Removed by Hand, Use the Puller
- Balancer Shaft - T10394- :
– Insert the Puller Jaw - T10394/1- from the Puller - Balancer

Shaft - T10394- .
– Insert the Puller - Balancer Shaft - T10394- and push the slid‐
ing sleeve in the direction of -arrow-.
AG. Volkswagen AG d
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ed
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ility
– Install the Puller - Unit Injector - T10055- into the Puller - Bal‐
ot
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ancer Shaft - T10394- and remove the balance shaft.

h re
hole
spec
Installing:
es, in part or in w
t to the co
Note
rrectness of i
Because of the small clearance between the balance shaft and

l purpos
cylinder block, the balance shaft may need to be cooled in order

to install it. Check if the balance shaft can be inserted into the
cylinder block without forcing it in. If it cannot, the balance shaft
nform
ercia
must be cooled before installing it.

m
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com
tio

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r

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1. Chain Drive 129

– Check the installation position for the balance shaft pipe

-arrow-. wage
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The tab -arrow- must be at the top. It is an anti-twistedmechanism.
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Note
ce
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un
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an
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itte
Press the pipe together slightly to position it in the installation po‐
y li
erm
ab
sition. Insert the Wrench - Pin Type - 3212- into the front pipe
ility
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openings and press together. Then insert the pipe with the
wit
Wrench - Pin Type - 3212- . is n
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ole,
spec
– Place the new balance shaft in a freezer for 30 minutes or
t to the co
spray it with commercially available cooling spray.
– Lubricate the balance shaft bearing with engine oil.
rrectne
– Install the exhaust camshaft balance shaft.
ss
– Before tightening the bolt -1- make sure the balance shaft lies
o
cial p
f
level on the crankcase.
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
If the balance shaft is not level, then the pipe for the balance shaft
sd
iva
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must be installed again.
pr
cum
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fo
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ng
t.
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– Install the drive chain for the balance shaft and the camshaft t. Cop py
timing chain. Refer to ⇒ page 117 .
rig
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co
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1.13 Valve Timing, Checking

♦ Dial Gauge Adapter - T10170A-
♦ Caliper gauge
page 91 .
– Remove the right wheel and remove the right wheel housing
liner.
– Turn the crankshaft with the socket SW 24 on the vibration
damper in the direction of the engine rotation until the mark‐
ings -arrows- are almost on top.
– Remove the spark plug from cylinder 1.

– Install the Dial Gauge Adapter - T10170A- all the way into the
spark plug thread.
. Volkswagen AG
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– Insert the DialVoGauge
lksw - 0-10mm - VAS6079-
oes
notusing the Exten‐
g
sion - T10170A-
ed by until stop and secure with theulocking
ara
nte
nut
-arrow-.
thoris
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au ra
– Turn
ss the crankshaft slowly in the direction of the engine
c
rota‐
ce
le
tion until the maximum dial reading is reached. When the

un
pt
maximum dial reading is reached (BDC of the meter) position
an
d
itte
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the piston at »TDC«.
erm
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ility
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Note
h re
ole,
spec
If the crankshaft was turned past »TCD«, turn the crankshaft two
t to the co
more turns in the direction of the engine rotation. Do not turn the
engine in the opposite direction of the engine rotation.
rrectne
– Measure the distance from the left outer edge -A- to the mark‐
s
ing -B- on the intake camshaft.
s o
cial p
f
• Specified value: 61 to 64 mm.
inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
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ng
t.
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Cop py
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rig ht
py by
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– Once the specified value is reached, measure the distance
AG.
between the marking on the intake camshaft -B- and the mark‐
ing on the exhaust camshaft -C-.
• Specified value: 124 to 126 mm.
Note
If one tooth has an offset, there will be a deviation of approxi‐

mately 6 mm from the specified value. Install the timing chain
once again if an offset is determined.
1. Chain Drive 131

2 Cylinder Head
⇒ “2.1 Overview - Cylinder Head”, page 132 .
⇒ “2.4 Compression, Checking”, page 168 .
⇒ “2.5 Vacuum Pump, Removing and Installing”, page 169 .
2.1 Overview - Cylinder Head
Note
♦ If the cylinder head bolt with the internal multi-point and collar
is installed, the camshafts must be removed before removing
the cylinder head bolt.
♦ Always replace self-locking nuts, bolts which have been tight‐
ened an additional turn as well as gaskets and seals. . Volkswagen AG
gen AG does
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♦ The plastic protectors installed to protect the open valves y V must
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only be removed immediately before mounting theriscylinder
ed
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1 - Cylinder Head Gasket
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❑ Always replace
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❑ Installed position: the
wit
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part number faces the
h re
hole
cylinder head
spec
es, in part or in w
2 - Bolt
t to the co
❑ 25 Nm
3 - Transport Strap
rrectness of i
4 - Bolt
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Refer to
nform
ercia
⇒ Fig. ““Cylinder Head

Tightening Sequence”“ ,
m
at
om
page 135
ion
c
in t
or
5 - Cylinder Head
his
ate
do
riv

p
cum
or
ling. Refer to
f
en
ng
⇒ “2.3 Cylinder Head,

t.
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op
Removing and Instal‐ C py
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ling”, page 136 . rig ht
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❑ Checking for distortion.
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Refer to
AG.
⇒ Fig. ““Cylinder Head,

Checking for Distor‐
tion”“ , page 135
6 - Cylinder Head Bolt
❑ Always replace
❑ Follow the sequence
when loosening. Refer
to
⇒ Fig. ““Loosen the Cyl‐
inder Head”“ ,
page 134

❑ Observe sequence for
tightening. Refer to ⇒ Fig. ““Cylinder Head Tightening Sequence”“ , page 135
7 - O-Ring
❑ Always replace
8 - Plugs
❑ 5 Nm
❑ with ball head for the engine cover
9 - Cap
AG. Volkswagen AG d
❑ With seal agen oes
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10 - O-Ring rised
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❑ Always replace s aut ra
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11 - Plugs
itte
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ab
12 - Bracket
ility
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13 - Bolt
h re
hole
❑ 9 Nm
spec
es, in part or in w
14 - Heat Shield
t to the co
15 - Bolt
❑ 20 Nm
rrectness of i
16 - Bolt
l purpos
❑ 20 Nm
nform
ercia
17 - To the Intake Hose/Turbocharger

m
at
18 - Bleed Pipe
om
ion
c
in t
19 - O-Ring
or
his
ate
❑ No replacement part
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or
20 - Seal
f
en
ng
t.
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❑ No replacement part t. Cop py
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21 - Engine Cover yri
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22 - Bolt
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❑ Tightening sequence. Refer to ⇒ Fig. ““Crankcase Ventilation, Tightening Sequence”“ , page 134
23 - Crankcase Ventilation
❑ Observe sequence for tightening. Refer to
⇒ Fig. ““Crankcase Ventilation, Tightening Sequence”“ , page 134
24 - To the Intake Manifold
25 - Seal
❑ No replacement part
26 - Seal
27 - Vacuum Pump
❑ Removing and installing. Refer to ⇒ “2.5 Vacuum Pump, Removing and Installing”, page 169 .
28 - Vacuum Pump Bolts
❑ 9 Nm
Replace after removing
2. Cylinder Head 133

29 - 9 Nm
❑ Engine code CBFA only
30 - Secondary Air Injection Solenoid Valve - N112-
❑ Removing and Installing. Refer to
⇒ “4.3 Secondary Air Injection Solenoid Valve N112 , Removing and Installing”, page 561 .
31 - Seal
❑ Always replace
32 - Retaining Plate
33 - Bolt
❑ 9 Nm
34 - Connection
❑ Engine code CBFA: before removal the Secondary Air Injection Solenoid Valve - N112- must be removed.
Refer to ⇒ “4.3 Secondary Air Injection Solenoid Valve N112 , Removing and Installing”, page 561 .
35 - O-Ring
❑ Always replace
❑ Coat with coolant
AG. Volkswagen AG d
36 - Bolt ksw
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❑ 25 Nm ed by gu
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37 - Transport Strap aut
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38 - Bolt
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❑ 9 Nm
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39 - Camshaft Position Sensor - G40-
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40 - Partition Plate
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hole
spec
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t to the co
Crankcase Ventilation, Tightening Sequence
– Tighten the crankcase ventilation bolts to 11 Nm in the se‐
quence -1 to 10-.
rrectness of i
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nform
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at
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ion
c
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ate
do
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Loosen the Cylinder Head

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If the cylinder head bolt with the internal multi-point and collar is
installed, the camshafts must be removed before removing the
cylinder head bolt.

– Loosen the cylinder head bolts in the sequence -1 to 5-.

Cylinder Head Tightening Sequence

– Tighten the cylinder head bolts in -1 to 5- sequence as follows.
1- Tighten to 40 Nm Using a Torque Wrench.
swage es n
2- Tighten an Additional 90° Using a Rigid Wrench. y Vo lk ot g
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3- Tighten an Additional 90° Using a Rigid Wrench.
thoris tee
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– Then tighten the bolts -arrows-. ss
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pt
1- Pre-Tighten the Bolts to 8 Nm.
du
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2- Tighten the Bolts an Additional 90° Using a Rigid Wrench.
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Cylinder Head, Checking for Distortion hole
spec
– Check the cylinder head at several locations for distortion us‐
es, in part or in w
t to the co
ing a Straight Edge - 500mm - VAS6075- and a feeler gauge.
♦ Maximum permissible distortion: 0.05 mm
rrectness of i
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nform
mercia
at
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ion
c
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ate
2.2 Engine Cover, Removing and Installing
do
priv
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Removing
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– Pull the engine cover at its attachment points -arrows- upward. t. C rig
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– Make sure the rubber buffers fit correctly into the mounts when
installing.
– Carefully press the engine cover back into the catch.
– To prevent damage to the engine cover, do not hit the engine
cover with fist or a tool.
2.3 Cylinder Head, Removing and Installing

⇒ “2.3.1 General Information”, page 136
⇒ “2.3.2 Cylinder Head, Removing and Installing”, page 137
⇒ “2.3.3 Cylinder Head and Camshaft Timing Chain, Removing
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and Installing”, page 158 swa
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♦ If the cylinder head bolt with the internal multi-point and collar
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is installed, the camshafts must be removed before removing
ot
the cylinder head bolt.

wit
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hole
♦ Different work procedures are necessary depending on which

spec
ones should be performed or depending on the guide rail ver‐

es, in part or in w
t to the co
sion. First check to see which guide rail is installed.

rrectness of i
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com
tion in
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Guide Rail Version, Checking:

page 91 .
– Check the glide rail -1- near the -arrows-.
A - Long Guide Rail
B - Short Guide Rail
Remove the Cylinder Head if a »short« Guide Rail Is Installed and
the Camshaft Timing Chain Is to Remain Installed:
Procedure. Refer to
⇒ “2.3.2 Cylinder Head, Removing and Installing”,
page 137 .
. Volkswagen AG
gen AG
does
Remove the Cylinder
Vol
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a
notRail Is Installed and
the Camshaft
ed Timing Chain Is Also to Be Removed:
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Procedure.
au
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⇒
s “2.3.3 Cylinder Head and Camshaft Timing Chain,c Remov‐
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Remove the Cylinder Head if a »long« Guide Rail Is Installed:

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Procedure. Refer to ility
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⇒ “2.3.3 Cylinder Head and Camshaft Timing Chain, Remov‐ wit

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2.3.2 Cylinder Head, Removing and Installing

t to the co

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mer

atio
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♦ Tensioner Locking Tool - T40267-

n
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or
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♦ Camshaft Locks - T40271-

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♦ Cylinder head bolt with Polydrive: Polydrive Bit Drive Socket -
T10070-
♦ Cylinder head bolt with internal multi-point: 12 mm Internal
Multi-Point Socket
♦ Engine Support - T10014-
♦ Puller - Ignition Coil - T40039-

Removing:
Note
G. Volkswage
♦ During installation, the cable
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location. o n ot g
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♦ Always seal th off any open channels in the intake and exhaust
o tee
or
tract withss suitable plugs. For example, from the Engine Bung
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Set - VAS6122- .
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– Remove the air filter housing. Refer to
h re
hole
spec
page 465 .
es, in part or in w
t to the co
– Remove the bolt -4-.
rrectness of i
– Disconnect the connectors -arrow- and free up the electric
wire.
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WARNING
nform
mercia
a
com
tion in
r
The cooling system is under pressure when the engine is

te o
thi
warm.
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fo
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– Remove front exhaust pipe with catalytic converter:
Golf and Eos. Refer to
Tiguan. Refer to
– Remove the right front wheel.

– Remove the charge air hose -A-.
AG. Volkswagen AG d
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– Disconnect the connectors -1 and 2- and free up the wire

or c
-arrows-.
thi
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AWD Vehicles:
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– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,

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All Vehicles:
– Remove bolts -1 and 2- and remove the turbocharger support.
– Remove the banjo bolt -2- and move the coolant line to the
side.
Vehicles with FWD:
– Remove the bolts -1- on the oil return line.
AWD Vehicles:
– Remove the oil return line bolts on the crankcase.
All Vehicles:
– Remove the bolt -3- on the oil supply line.
– Only for vehicles with a sound generator: remove the charge
air guide for the sound generator.
– Remove the connector -1- on the Camshaft Adjustment Valve
1 - N205- .
– Disconnect the connectors from the ignition coils and free up

the wiring harness.
AG. Volkswagen AG d
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– Remove the ignition coils using the Puller - Ignition Coil -

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T40039- .
h re
hole
spec
– Disconnect the crankcase ventilation hose -1-.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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Rep. Gr.15 - Cylinder Head, Valvetrain Prote
cted AG.
agen
– Remove the bolts -arrows-. agen

AG. Volkswagen AG d
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– Remove the air duct pipe bolt -arrow-.
rrectness of i
– Loosen the hose clamp -1- and remove the air guide pipe to‐
gether with the crankcase ventilation.
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WARNING
nf
ercia
orm
m
The fuel line is under pressure.
atio
om
n in
c
Fuel poses a risk of injury to the eyes and skin.

or
thi
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sd
a
Wear protective eyewear and protective clothing to avoid injury

iv
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and contact with skin. Place a cleaning cloth around the con‐
o
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f
en
nection point before loosening hose connections. Carefully
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open the connection point to release the pressure. ht. Cop py
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– Disconnect the wires -1 to 3- from the fuel transfer point.
1) Vent line
2) Vacuum line (only CBFA, CCTA and CCTB)
3) Fuel supply line
– Disconnect the coolant line to the coolant expansion tank

-arrow-.

– Remove the coolant hoses -arrows- from the coolant pipe.

– Disconnect the ground cable -3- and loosen the bolt -4-.
– Remove the bolts -1 through 3- and remove the heat shield

together with the coolant pipe.
– Disconnect the oil supply line -4- from the turbocharger.
AG. Volkswagen AG d
agen oes
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Note
es, in part or in w
t to the co
Remove the heat shield bolt -2- using a 6 mm hex fitting socket
-A-. The hex socket must be at least 5 cm -B- long. A socket that
rrectness of i
tapers to 6 mm at the tip is too wide.

l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
cum
for
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ng
t.
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Prote AG.

– Disconnect the connector -2- from the Fuel Pressure Regula‐

tor Valve - N276- .
AG. Volkswagen AG d
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Engine Code CBFA:

un
pt
an
d
itte
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– Disconnect the connector -A- and hose -B- from the Secon‐
rm
ab
dary Air Injection Solenoid Valve - N112- .
pe
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove the bolts -arrows- to loosen the coolant pipe.
nform
ercia
All:
m
a
com
tion in
– Disconnect the coolant hose from the side connection on the
r
te o
thi
cylinder head.
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– Disconnect the connectors -1 through 4-.

– Free up the wire -5-.
– Disconnect the vacuum line -6- leading to the EVAP canister.
Scirocco:

– Disconnect the vent line -1-, unlock the EVAP canister in di‐
-arrow B-.
All:
– Disconnect the connectors -1- and pull the connector out of
the retainer.
lkswage es n
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ir se tee
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– Remove the bolts -arrows- and then remove the coolant pipes
ility
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from the intake manifold.
wit
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nf
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m
atio
– Remove the intake manifold bracket by removing the nut -1-

om
n in
and bolt -2-.

or c
thi
te
– Remove the oil filter.

sd
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f
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t.
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– Disconnect the coolant hoses -arrows- and free them up.

AG. Volkswagen AG d
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pt
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Valve 1 - N205- .
rrectness of i
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page 91 .
nform
ercia
Caution
m
at
om
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ate
do
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– Remove the control valve in direction of -arrow- using the Cop py
t. rig
Central Valve Assembly Tool - T10352- . opyri
gh by
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Prote AG.
– Remove the bolts -arrows- and remove the bearing bracket.


– Mark the camshaft timing chain and the cylinder head

-arrows- to match the marking on the chain sprockets -1- with
a waterproof marker.
– In addition, mark the camshaft timing chain to the camshaft
timing chain guide rail -2- with a waterproof marker.
lkswage es n
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– Remove the plug -arrow-. orise tee
th or
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es, in part or in w
t to the co
rrectness of i

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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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ng
t.
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– Remove the bolt -arrow-.

Two Different Chain Tensioners May Be Installed Depending on
the Version. Version 1:
Note
♦ If the Chain Tensioner Lever - T40243- cannot be inserted, the

distance between the timing chain and the oil baffle on the
lower cover is too small. The lower cover must then be re‐
moved.
♦ Passat and CC. Refer to
♦ Golf and Eos. Refer to
♦ Tiguan. Refer to
AG. Volkswagen AG d
agen oes
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– Lift up the locking wedge for bthe y V chain tensioner in direction of t gua
o
-arrow 1-. Sand the end of ris the Locking Pin (3 pc.) - T40011-
ed ran
tee
tho
down to a point. A screwdriver with a blade width of approxi‐ or
au ac
mately 1.5 mm can salso
s be used.
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Caution
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carefully.
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t to the co
– Slowly press and hold the Chain Tensioner Lever - T40243-

in the direction of -arrow 2-.
rrectness of i
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mercia
a
com
tion in
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. Volkswage AG n AG d
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– Secure the chain tensioner using the Locking Pind b(3y Vpc.) - gu
ara
T40011- . rise nte
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Version 2: ss c
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pt
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Note
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moved.
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♦ Golf and Eos. Refer to

nf
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atio
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c

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– Press the chain tensioner circlip -arrow- together, slowly press

t.
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and hold the Chain Tensioner Lever - T40243- in direction of C py
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-arrow-.
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T40267- .
Continuation for All:


direction of the -arrow 2-. If necessary, turn the intake cam‐
shaft with a wrench in the direction of the -arrow 1-.

cylinder head. Counterhold the camshaft with a wrench in a
clockwise direction -arrow-.
– Remove the bolt -A- and slide the tensioning rail down. While
doing so continue counterholding the camshaft.
lkswage es n
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ir se tee
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spec
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t to the co
– Turn the exhaust camshaft clockwise in direction of -arrow 1-

rrectness of i
until the Camshaft Lock - T40271/1- can be slid into the chain
sprocket splines in direction of -arrow 2-.
l purpos
nform
mercia
at
om
ion
c
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ate
do
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for
en
ng
t.
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– Remove the upper guide rail -1- by unlocking the catch with a
screwdriver and pushing the guide rail forward. Mark the po‐
sition of the chain sprocket -arrow- to the camshaft locating
tool.
– Remove camshaft timing chain from chain sprockets.
Caution
Risk of damaging valves and piston crowns.

♦ If the camshaft timing chain was removed from the cylin‐
der head, then the crankshaft may not be turned farther.
– Turn the sealing plug -arrows- counterclockwise 90° in the di‐

rection of -arrow- and remove it. AG. Volkswagen AG d
agen oes
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– Remove the ball head -1 through 2-. by Vol
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– Remove the cap. thor eo
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ility
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es, in part or in w
t to the co
– Internal multi-point bolt with collar: remove the camshafts. Re‐
fer to ⇒ “3.2 Camshaft, Removing and Installing”, page 173 .
rrectness of i
Remove the cylinder head bolts in the sequence -1 to 5-.
l purpos
– Polydrive bolts: remove the cylinder head bolts with the Poly‐
drive Bit Drive Socket - T10070- in the order -1 through 5-.
nf
ercia
orm
m
atio
Note
om
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♦ Make sure all wires and cables are disconnected.

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♦ Pay attention to the tension and guide tracks when lifting the
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f
cylinder head.
en
ng
t.
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– Remove the cylinder head.
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– Lay the cylinder head on a soft surface, such as foam. cted agen
Prote AG.
Install the cylinder head. Refer to ⇒ page 154 .
If the Camshafts Are Replaced, the Previous Markings Must Be

Transferred. For This the following Steps Are Important:
– On the removed cylinder head, mark the camshaft chain
sprockets to the Camshaft Locks - 1 - T40271/1- and Camshaft
Locks - 2 - T40271/2- -arrow-.
Note
The following distance measurement is used later to check wheth‐

er the markings were transferred correctly.

– Measure the distance from the left outer edge of the bar -A- to
the marking -B- on the intake camshaft and write down the
value.
AG. Volkswagen AG d
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– Measure the distance between the markingbyon V the intake cam‐
ol
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ara
shaft -B- and the marking on the exhaust rise camshaft -C- and
d
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write down the value. utho eo
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ility
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– Turn the intake camshaft with a wrench in the direction of
rrectness of i
-arrow 1-, slide the Camshaft Lock - Component 2 - T40271/2-
out of the chain sprocket splines in direction of -arrow 2- and
l purpos
bring the camshaft into the rest position.
nf
– Remove the Camshaft Lock - Component 2 - T40271/2- .
ercia
orm
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– Turn the exhaust camshaft with a wrench in the direction of

out of the chain sprocket splines in direction of -arrow 2- and
bring the camshaft into the rest position.
Now Install the Cylinder Head and Transfer the Markings That
Were Made When It Was Removed.
AG. Volkswagen AG d
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cylinder head to be installed.
hole
spec
– Turn the intake camshaft in direction of -arrow 1- until the

es, in part or in w
t to the co
marking -3- aligns with the Camshaft Lock - Component 2 -

T40271/2- .
rrectness of i
chain sprocket splines in the direction of -arrow 2-.

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– Compare the distance from the left outer edge of the bar -A-
to the marking -B- with the previously noted value.
cylinder head.
– Turn the exhaust camshaft in the direction of -arrow 1- until
the marking -3- aligns with the Camshaft Lock - Component 1
- T40271/1- .

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– Compare the distance between the marking on the intake

camshaft -B- to the marking on the exhaust camshaft -C- with
the previously noted value.
Install the Cylinder Head: olkswage es n
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cylinder head bolts in the cylinder block.
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Risk of damaging the valves and piston heads after working on

valvetrain.
♦ To ensure valves do not strike pistons when starting, care‐
fully rotate engine at least two full revolutions.

Note

turn.
♦ Replace self-locking nuts, gaskets, seals and O-rings.
♦ If a replacement cylinder is installed, the contact surfaces be‐
tween the hydraulic adjusting elements, roller rocker levers
and cam running surfaces must be lubricated before installing
the camshafts.
♦ The hose supports, air duct pipes and hoses must be free of
oil and grease before installing.
♦ Secure all hose connections with hose clamps that match the
ones used in series production. Refer to the Parts Catalog.
♦ To mount the charge hoses on their connectors securely,
spray the bolts on the usedAGclamps
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Caution
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By turning the crankshaft, the timing chain tightens upward so

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Caution
By turning the crankshaft, the timing chain tightens upward so

that it does not jam.


– Position the markings on the chain links -arrows- at the chain

sprockets -1- to mount the camshaft timing chain.
– Install the upper guide rail -2-.
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-arrow 1- until the Camshaft Locks - Component 1 - T40271/1-
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the chain sprocket splines -2-. If necessary, slightly turn the
intake camshaft with the wrench in direction of -arrows 1-.
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– Check the markings. The camshaft timing chain and cylinder

head -arrows- must align with the markings on the chain
s
sprocket -1-.
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– The markings for the camshaft timing chain and the camshaft
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T40011- or the Tensioner Locking Tool - T40267- .
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moval, noting the following:
– Change the engine oil.
– Fill with coolant. Refer to
2.3.3 Cylinder Head and Camshaft Timing

Chain, Removing and Installing

♦ Cylinder head bolt with Polydrive: Polydrive Bit Drive Socket -

T10070-
♦ Cylinder head bolt with internal multi-point: 12 mm Internal
Multi-Point Socket
Removing:
Note
♦ Before installing the cylinder head the engine support and the
engine mount are temporarily re-installed because the eyes
from the engine support bridge are secure on the cylinder
head.
♦ When installing, secure all cable ties back to same positions.
♦ Close the open channels from the intake and exhaust tract with
suitable plugs from the Engine Bung Set - VAS6122- .

page 465 .
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4-Cylinder Fuel Injection Engines (1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015
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The cooling system is under pressure when the engine is
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– Remove the right front wheel.
– Remove the charge air hose -A-.


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AWD Vehicles:
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All Vehicles:
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– Remove bolts -1 and 2- and remove the turbocharger support.

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– Remove the banjo bolt -2- and move the coolant line to the
m
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– Remove the oil return line bolts on the crankcase.
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All Vehicles:
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– Remove the connector -1- on the Camshaft Adjustment Valve
1 - N205- .
rrectness of i
– Disconnect the connectors from the ignition coils and free up
the wiring harness.
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– Loosen the hose clamp -1- and remove the air guide pipe to‐
gether with the crankcase ventilation.
WARNING

open the connection point to release the pressure.
– Disconnect the wires -1 to 3- from the fuel transfer point.

1) Vent line
2) Vacuum line
3) Fuel supply line

-arrow-.
– Remove the coolant hoses -arrows- fromgthe coolant
en AG. Volkswapipe.
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– Disconnect the ground cable -3- and loosen the bolt -4-.
es, in part or in w
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2. Cylinder Head

together with the coolant pipe.
Note
Remove the heat shield bolt -2- using a 6 mm hex fitting socket
-A-. The hex socket must be at least 5 cm -B- long. A socket that
tapers to 6 mm at the tip is too wide.
AG. Volkswagen AG d
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tor Valve - N276- .

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Engine Code CBFA:

– Disconnect the connector -A- and hose -B- from the Secon‐
dary Air Injection Solenoid Valve - N112- .
– Remove the bolts -arrows- to loosen the coolant pipe.

All:
– Disconnect the coolant hose from the side connection on the
cylinder head.

– Free up the wire -5-.
– Disconnect the vacuum line -6- leading to the EVAP
olks
wagcanister.
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– Disconnect the connectors -1- and pull the connectors
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– Disconnect the connectors -2 throughss a4-.
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– Remove the bolts -arrows- and then remove the coolant pipes
from the intake manifold.
rrectness of i
– Remove the intake manifold bracket by removing the nut -1-
and bolt -2-.
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– Remove the oil filter.
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– Disconnect the coolant hoses -arrows- and free them up.

– Remove the camshaft timing chain. Refer to
page 111 .
– Reinstall the engine support and engine mount and tighten the
bolts hand-tight.
– Disengage the Engine Support Bridge - 10-222A- spindles.
– Turn the sealing plug -arrows- counterclockwise 90° in the di‐
rection of -arrow- and remove it.
– Remove the ball head -1 and 2-.
– Remove the cap.

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– Remove the bolts -arrows-. ss
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– Internal multi-point bolt with collar: remove the camshafts. Re‐
pt
du
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fer to ⇒ “3.2 Camshaft, Removing and Installing”, page 173 .
itte
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Remove the cylinder head bolts in the sequence -1 to 5-.
erm
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– Polydrive bolts: remove the cylinder head bolts with the Poly‐
wit
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drive Bit Drive Socket - T10070- in the order -1 through 5-.
h re
hole
spec
es, in part or in w
t to the co
Note
Make sure all wires and cables are disconnected.
rrectness of i
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– Remove the cylinder head.
– Lay the cylinder head on a soft surface, such as foam.
nform
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Install the Cylinder Head:

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♦ Replace the gaskets, seals and self-locking nuts. cted agen
Prote AG.
♦ The hose supports, air duct pipes and hoses must be free of
oil and grease before installing.
♦ Secure all hose connections with standard production hose
clamps. Refer to the Parts Catalog.
♦ Spray the bolts on the used clamps with rust remover before
installing.
– Only unpack the new cylinder head gasket immediately prior

to installation. The silicon layer and the cylinder head gasket
recessed area must not be damaged.
– Carefully remove the sealant residue from cylinder head and
cylinder block. Make sure that no long grooves or scratches
result. Carefully remove all lapping and sanding residue.
– Clean the cylinder head bolt blind holes. If necessary blow out
with compressed air.

– Position the cylinder head gasket.

♦ Pay attention to centering pins in cylinder block -arrows-.
♦ Pay attention to the cylinder head gasket installation position:
the part number must be readable from the intake side.
– If the crankshaft was turned in the meantime: bring the piston
for cylinder 1 to the upper TDC and then turn the crankshaft
back just a little.
– Position the cylinder head.
– Insert cylinder head bolts and tighten by hand.
– Tighten the cylinder head. Tightening sequence. Refer to
⇒ Fig. ““Cylinder Head Tightening Sequence”“ , page 135
– Support the engine again in the installation position using the
Engine Support Bridge - 10-222A- .
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– Remove the engine mount and the engine support. agen oes
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– Install the drive chain for the balance shaft and the camshaft
orise nte
timing chain. Refer to ⇒ page 117 . aut
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Further assembly is performed in the reverse order of removal.
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Observe the following:
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– Replace the engine oil. Refer to ⇒ Maintenance ; Booklet
erm
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24.1 ; Procedure Descriptions; Engine Oil, Draining or Ex‐
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tracting, Changing Oil Filter and Filling Oil .
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– Fill with new coolant. Refer to
spec
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2.4 Compression, Checking
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♦ Spark Plug Removal Tool - 3122B-

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♦ Compression Tester Kit - VAG1763-
n
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♦ Compression Tester Kit - Adapter 5A - VAG1381/5A-

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♦ Fuel Injection Gauge Kit - Adapter - VAG1381/1-

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Test Sequence:
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♦ Follow all Safety Precautions. Refer to

⇒ “1.2 Safety Precautions”, page 564 .
♦ Engine oil temperature: minimum 30 °C (86 °F)
♦ Battery voltage at least 12.7 V
Proceed as follows:
– Remove the ignition coil with power output stage. Refer to
⇒ “1.4 Ignition Coils with Power Output Stages, Removing and
– Remove the spark plugs with the Spark Plug Removal Tool -
3122B- .

– Check the compression using the Compression Tester Kit -

VAG1763- , Compression Tester Kit - Adapter 1 - VAG1381/1-
and Compression Tester Kit - Adapter 5A - VAG1381/5A- .
Note
Refer to the Operating Instructions for information on using the

tester.
– Operate the starter until the tester no longer indicates a pres‐

sure increase.
Compression values:
New Pressure Pressure Wear Limit Pressure Deference
Between Cylinders
11.0 to 14.0 bar 7.0 bar (101.52 psi) maximum 3.0 bar
(160 to 203 psi) (43.5 psi)
– Install the sparks plugs. Refer to
⇒ “1.3 Overview - Ignition System”, page 565 for the tighten‐
ing specification.
– Install the ignition coil with power output stage. Refer to
Note
By separating the connections, DTCs will be stored. After the test,

check the DTC memory and erase, if necessary.
– Read the engine control module DTC memory. Refer to Vehi‐

cle Diagnostic Tester .
2.5 Vacuum Pump,

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Proceed as follows:
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page 465 .
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– Remove the high pressure pump with the »roller tappet«. Re‐
spec
fer to
es, in part or in w
t to the co
⇒ “2.17 High Pressure Pump, Removing and Installing”, page

487 .
– Disconnect the ground wire -3- and remove the bolt -4-.
rrectness of i
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2. Cylinder Head
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– Remove the vacuum hose -1- from the vacuum pump.
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– Remove the bolts -arrows- and remove the vacuum pump.
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Note
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Do not disassemble the vacuum pump.
spec
es, in part or in w
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Installing:
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Installation is the reverse of removal, noting the following:
l purpos
– Clean the sealing surfaces.
nform
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– Install the seal on the vacuum pump, install the two bolts and
m
then mount it on the cylinder head.
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3 Valvetrain
⇒ “3.1 Overview - Valvetrain”, page 171 .
⇒ “3.2 Camshaft, Removing and Installing”, page 173 .
⇒ “3.3 Camshafts, Checking Axial Play”, page 188 .
⇒ “3.4 Valve Stem Seals, Always replace”, page 188 .
⇒ “3.5 Valve Guides, Checking”, page 191 .
3.1 Overview - Valvetrain
1 - Exhaust Valve
❑ Do not rework, only lap‐
ping is permitted
❑ Valve Dimensions. Re‐
fer to
⇒ Fig. ““Valve Dimen‐
sions”“ , page 172 .
❑ Valve Guides, Check‐
ing. Refer to
⇒ “3.5 Valve Guides,
Checking”, page 191 .
2 - Cylinder Head
3 - Valve Guide
❑ Checking. Refer to
⇒ “3.5 Valve Guides,
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5 - Valve Spring ised b ara
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6 - Valve Spring Retainer s aut ra
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7 - Valve Retainers
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❑ Lubricate contact surfa‐

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9 - Exhaust Camshaft
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❑ Check radial clearance

using Plastigage® (roller
rocker lever removed)
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❑ Radial clearance with

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bearing diameter 24
mm: 0.024 to 0.066 mm
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❑ Radial clearance on
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❑ Run-out: maximum 0.04 mm

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❑ Removing and installing. Refer to ⇒ “3.2 Camshaft, Removing and Installing”, page 173 .
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10 - Cylinder Head Cover

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❑ Always replace
3. Valvetrain 171
❑ Tightening sequence. Refer to ⇒ Fig. ““Cylinder Head Cover Tightening Sequence”“ , page 172
12 - O-Ring
❑ Always replace
❑ Coat with engine oil
13 - Plugs
14 - Intake Camshaft
❑ Check radial clearance using Plastigage® (roller rocker lever removed)
❑ Radial clearance with bearing diameter 24 mm: 0.024 to 0.066 mm
❑ Run-out: maximum 0.04 mm
❑ Removing and installing. Refer to ⇒ “3.2 Camshaft, Removing and Installing”, page 173 .
15 - Cap
❑ Always replace
❑ Removing: with the cylinder head cover installed, pierce through one side of the cover with a punch and
pry it out
❑ Installing: without sealant, press in 1 to 2 mm using the Seal Installer - Selector Shaft Oil Seal - T10174-
16 - Intake Valve
❑ Do not rework, only lapping is permitted
❑ Valve Dimensions. Refer to ⇒ Fig. ““Valve Dimensions”“ , page 172 .
❑ Valve Guides, Checking. Refer to ⇒ “3.5 Valve Guides, Checking”, page 191 .
Cylinder Head Cover Tightening Sequence

– Replace the bolts.
1. Hand-tighten bolts in several steps in -1 to 6- sequence.
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Intake and exhaust valves must not be reworked. Only lapping is

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Dimension Intake Valve Exhaust Valve

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Diameter mm 33.85 ± 0.10 28.0 ± 0.1

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♦ If the cylinder head cover was removed, the cap must be re‐
placed.
♦ During installation, the cable ties must be installed at the same
location.
♦ The cylinder head and the cylinder head cover must be re‐
placed together.
♦ Do not start the engine for approximately 30 minutes after in‐
stalling the camshafts. The hydraulic adjusters must seat
themselves (otherwise the valves will crash into the pistons).
♦ After working on the valvetrain and lifters, carefully rotate the
crankshaft by hand at least two full revolutions to be sure that
valves do not strike the pistons when starting.
♦ Always replace the gaskets and seals.
Removing:
Note
Use Chain Tensioner Lever - T40243- to install, when the chain

is ok. But if the chain is to long, remove the lower chain cover
before you can install Chain Tensioner Lever - T40243-

– Remove the vacuum pump. Refer to
⇒ “2.5 Vacuum Pump, Removing and Installing”, page 169 .
3. Valvetrain 173

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– Open the clamps
ed -1 and 2- and remove the air guide rpipe.
by ua
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– Disconnect au the connector -1- from the Camshaft Adjustment
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Valve 1 - N205- .
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page 91 .
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– Remove the control valve in direction of -arrow- using the
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Central Valve Assembly Tool - T10352- . co Vo
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Caution
– Remove the bolts -arrows- and remove the bearing bracket.


– Mark the camshaft timing chain and the cylinder head

-arrows- to match the marking on the chain sprockets -1- with n AG. Volkswagen AG
a waterproof marker. olks
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– In addition, mark the camshaft timing chain to therisecamshaft
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timing chain guide rail -2- with a waterproof marker.
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– Remove the plug -arrow-.
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3. Valvetrain 175

Two Different Chain Tensioners May Be Installed Depending on
the Version. Version 1:
Note
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♦ If the Chain Tensioner Lever
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db chain and the oil baffle on theuaran
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or
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– Lift up the locking wedge for the chain tensioner in direction of
l purpos
-arrow 1-. Sand the end of the Locking Pin (3 pc.) - T40011-
down to a point. A screwdriver with a blade width of approxi‐
mately 1.5 mm can also be used.
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– Secure the chain tensioner using the Locking Pin (3 pc.) -

T40011- .
Version 2:
Note

moved.
♦ Golf, Eos, Scirocco. Refer to
– Press the chain tensioner circlip -arrow- together, slowly press

and hold the Chain Tensioner Lever - T40243- in direction of
-arrow-.
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T40267- .
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3. Valvetrain 177
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direction of the -arrow 2-. If necessary, slightly turn the intake
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ility
camshaft with a wrench in the direction of -arrow 1-.
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cylinder head. Counterhold the camshaft with a wrench in a
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clockwise direction -arrow-. p by
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– Remove the bolt -A- and slide the tensioning rail down. While Prote AG.
doing so continue counterholding the camshaft.
– Turn the exhaust camshaft clockwise in direction of -arrow 1-

until the Camshaft Lock - T40271/1- can be slid into the chain
sprocket splines.

– Remove the upper guide rail -1- by unlocking the catch with a
screwdriver and pushing the guide rail forward. Mark the po‐
sition of the chain sprocket -arrow- to the camshaft locating
tool.
– Remove camshaft timing chain from chain sprockets.
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♦ Make certain that the timing chain remains tensioned by
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If the Camshafts Are Replaced, the Previous Markings Must Be
Transferred. For This the following Steps Are Important:
rrectness of i
– Before removing the camshafts, mark the camshaft sprockets
to the Camshaft Locks - Component 1 - T40271/1- and Cam‐
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shaft Locks - Component 2 - T40271/2- -arrow-.
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The following distance measurement is used later to check wheth‐

or
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er the markings were transferred correctly.

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– Measure the distance from the left outer edge of the bar -A- to C py
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– Measure the distance between the marking on the intake cam‐

shaft -B- and the marking on the exhaust camshaft -C- and
write down the value.
3. Valvetrain 179
– Turn the intake camshaft with a wrench in the direction of

out of the chain sprocket splines in the direction of -arrow 2-
and bring the camshaft into the rest position.
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– Turn the exhaust camshaft with a wrench in the direction of

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out of the chain sprocket splines in the direction of -arrow 2-

and bring the camshaft into the rest position.
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– Remove the ignition coil with power output stage. Refer to
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– Loosen the hose clamp d by V-1- and remove the air guide pipe uato‐
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– Disconnect thess vacuum line -1- and free up the line.
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– Disconnect the connector -2- from the Camshaft Position Sen‐
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– Remove the cylinder head cover bolts in -1 to 6- sequence.
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– Remove the cylinder head cover.
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– Remove the camshafts.
es, in part or in w
t to the co
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3. Valvetrain 181
– Prevent dirt and sealant residue from entering cylinder head.

Camshafts, Installing:
Transfer the Self-Applied Markings from the Removed Camshaft
to the New Camshaft.
⇒ “3.1 Overview - Valvetrain”, page 171 .
Note
♦ Do not start the engine for approximately 30 minutes after in‐

stalling the camshafts. The hydraulic adjusters must seat
themselves (otherwise the valves will crash into the pistons).
♦ After working on the valvetrain and lifters, carefully rotate the
crankshaft by hand at least two full revolutions to be sure that
valves do not strike the pistons when starting.
♦ Sealing surfaces must be completely free of oil and grease.
♦ The pistons must not be positioned at TDC.
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♦ Make sure that all roller rocker levers make contact
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♦ Note the expiration date of the or
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♦ Prevent dirt and sealant residue from entering cylinder head.
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– Remove any sealant residue on the cylinder head using the
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flat-blade scraper.
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WARNING
Wear protective eyewear.

rrectness of i
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– Remove any sealant residue of the groove in the cylinder head

cover as well as from any sealing surface using, for example,
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a rotating plastic brush.

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proximately 2 mm).
– Lubricate the running surfaces of both camshafts.
– Place the camshaft into the cylinder head; the recesses

-arrows- must be perpendicular to each other.
– Replace the cylinder head cover bolts.
– Apply the Silicone Sealant - D 154 103 A1- onto the clean cyl‐
inder head cover sealing surface as shown -arrows-.
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♦ The cylinder head cover must ir se
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♦ Note the expiration date for the sealant.

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– Tighten bolts in several stages in the tightening sequence.

hole
Refer to
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⇒ Fig. ““Cylinder Head Cover Tightening Sequence”“ ,

es, in part or in w
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page 172 .
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3. Valvetrain 183
Note
♦ Make sure the cylinder head cover is not tilted.

♦ Drive the cap -1- in without sealant using the Seal Installer -
Selector Shaft Oil Seal - T10174- .
♦ Dimension -a-: 1 to 2 mm
Caution
Danger of damaging the valves, piston crowns and lower tim‐

ing chain cover.
♦ Make certain that the timing chain remains tensioned by
hand when turning the crankshaft.
♦ Panels are installed on the lower timing chain cover to
prevent the chain from falling down. The panels can bend
if the crankshaft is rotated when the chain is loose.

Damper - T10355- into the »TDC« position -arrow-.
– Turn the intake camshaft in direction of -arrow 1- until the
marking -3- aligns with the Camshaft Lock - Component 2 -
T40271/2- .
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– Turn the exhaust camshaft in the direction of -arrow 1- until

the marking -3- aligns with the Camshaft Lock - Component 1
- T40271/1- .
For New Camshafts:
– Compare the distance from the left outer edge of the bar -A-
to the marking -B- with the previously noted value.
– Compare the distance between the marking on the gintake

en AG. V
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camshaft -B- to the marking on the exhaust ycamshaft
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Continuation for All: aut or
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– Position the markings on the chain links -arrows- at the chain

sprockets -1- to mount the camshaft timing chain.
rrectness of i
– Install the upper guide rail -2-.

l purpos
Note
nform
mercia
Use the help of a second technician to hold the exhaust camshaft

com
tion in
in place.
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3. Valvetrain 185
– Slowly turn the exhaust camshaft in the direction of the

-arrow 1- until the Camshaft Locks - component 1 - T40271/1-
can be pulled from the chain sprocket splines.
sition.

AG. Volkswagen AG d
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the chain sprocket splines in direction of -arrow 2-. If neces‐

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direction of -arrow 1-.

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– Check the valve timing. The camshaft timing chain and cylin‐
der head -arrows- must align with the markings on the chain
sprockets -1-.
– The markings for the camshaft timing chain and the camshaft
timing chain guide rail -2- must align.
– The notch on the vibration damper must be opposite the mark‐
ing on the lower timing chain cover -3-.
Note
If the self-made markings are no longer visible, check the valve

timing. Refer to ⇒ “1.13 Valve Timing, Checking”, page 130 .
– Carefully attach the bearing bracket. Do not tilt it. Hand-tighten

the bolts -arrows-.
– Depending on the version, remove either the Locking Pin -
T40011- or the Tensioner Locking Tool - T40267- .
– Tighten the bolts -arrows-. Refer to
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– Install the bolt -arrow-.

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Note
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If the markings on the drive chain and guide rail -2- do not align
s
iva
do
even though the engine is at »TDC«, the drive chain has skipped
r
rp
cum
on the crankshaft chain sprocket. Check the valve timing. Refer

fo
en
g
to ⇒ “1.13 Valve Timing, Checking”, page 130 . If the timing does

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not agree, the camshaft timing chain must be positioned »again«. C py
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3. Valvetrain 187
3.3 Camshafts, Checking Axial Play

Test Sequence
– Perform the measurement with guide frame removed.
– Place camshaft to be checked in guide frame.
– Secure the Dial Gauge - 0-10mm - VAS6079- with the Dial
Gauge Holder - VW387- on the cylinder head.
– Press the camshaft against the dial gauge by hand.
– Set the dial gauge to “0”.
– Push the camshaft off the dial gauge and read the value:
• Axial play: 0.05 to 0.17 mm.
3.4 Valve Stem Seals, Always replace

(With cylinder head installed)
♦ Spark Plug Removal Tool - 3122B-
♦ Puller - Valve Seal - 3364- n AG. Volkswagen AG do
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♦ Seal Installer - Valve Stem - 3365- d byV ua
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♦ Valve Cotter Tool Kit - Adapter
autho
- T40012- or
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♦ Valve Keeper Tool Kit - VAS5161A- .

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♦ Valve Cotter Tool Kit - Guide Plate 19C - VAS5161/19C-

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Removing the Valve Stem Seals:

h re
hole
– Remove the camshafts. Refer to

spec
es, in part or in w
⇒ “3.2 Camshaft, Removing and Installing”, page 173 .

t to the co
– Remove roller rocker levers and place them on a clean sur‐

face. While doing this, make sure that roller rocker levers are
not interchanged.
rrectness of i
– Remove the spark plugs using the Spark Plug Removal Tool
l purpos
- 3122B- .
– Fasten the Valve Cotter Tool Kit - Guide Plate 19C -
nform
ercia
VAS5161/19C- with the Valve Cotter Tool Kit - Knurled Thumb

m
Screws M6 (2 pc) - VAS5161/12- onto the cylinder head as

com
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shown.
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– Adjust the piston of the respective cylinder to “bottom dead

s
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– Install the Valve Cotter Tool Kit - Adapter - T40012- into the
spark plug thread and connect the compressed air of at least
6 bar (87 psi) pressure.
– Loosen the secure fitting valve retainers using the Valve Cotter
Tool Kit - Punch - VAS5161/3A- and a plastic mallet.
For the Intake Side

– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with
the Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -
VAS5161/5- in the center thread of the Valve Cotter Tool Kit -
Guide Plate 19C - VAS5161/19C- .
– Place the Valve Cotter Tool Kit - Assembly Cartridge -
VAS5161/8A- in the Valve Cotter Tool Kit - Guide Plate 19C -
VAS5161/19C- .
– Engage the Valve Cotter Tool Kit - Pressure Fork with Lever
for Assembly Cartridge - VAS5161/2- on the Valve Cotter Tool
Kit - Retainer - VAS5161/6- . wage
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For the Exhaust Side tho eo
s au ra
c
– Install the Valve Cotter Tool
s Kit - Retainer - VAS5161/6- with
ce
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the Valve Cotter Tool Kit - Guide Forks M6/M8 Threaded -

nl
pt
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an
VAS5161/5- in the outer threads of the Valve Cotter Tool Kit -
itte
Guide Plate 19C - VAS5161/19C- . y li

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– Press the Valve Cotter Tool Kit - Assembly Cartridge - wit

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VAS5161/8A- downward. At the same time, turn the knurled

h re
screw of the Valve Cotter Tool Kit - Assembly Cartridge -

hole
spec
VAS5161/8A- to the right, until the points engage in the valve

es, in part or in w
retainers.
t to the co
– Lightly move knurled bolt back and forth, causing the valve
retainers to be pressed apart and be captured in the installa‐
rrectness of i
tion cartridge.
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– Release the Valve Cotter Tool Kit - Pressure Fork with Lever
for Assembly Cartridge - VAS5161/2- .
nform
ercia
– Remove the Valve Cotter Tool Kit - Assembly Cartridge -

VAS5161/8A- .
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3. Valvetrain 189
– Remove the valve stem seals using Puller - Valve Seal -

3364- .
– If the Puller - Valve Seal - 3364- cannot be used due to re‐

stricted clearance, drive the spring pin -arrow- out with a drift
and remove the impact attachment. AG. Volkswagen AG d
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– Place the lower part of the Puller - Valve Seal - 3364- onto d by the
V o gu
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valve stem seal. orise nte
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– Install a drift -1- into the hole into the lower partssof the puller.
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– Place a lever at the puller and pull out the valve stem seal in
es, in part or in w
t to the co
direction of -arrow-.
Installing Valve Stem Seals:
rrectness of i
– Place plastic sleeve -A- on the valve stem to prevent damage
to the new valve stem seals -B-.
l purpos
– Oil the sealing lip of valve stem seal -B-, insert into Seal In‐
staller - Valve Stem - 3365- and carefully slide onto the valve
nform
ercia
guide.
m
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– Remove the plastic sleeve -A-.

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– Insert valve spring and valve spring retainer.

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Intake Side
– Install the Valve Cotter Tool Kit - VAS5161A- as shown.
Exhaust Side
– Install the Valve Cotter Tool Kit - VAS5161A- as shown.
AG. Volkswagen AG d
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Note rised
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♦ If the valve retainers were removed from the installation car‐ ss c
ce
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tridge, they must then be inserted into the Valve Cotter Tool
un
pt
Kit - Valve Insertion Device - VAS5161/18- .

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♦ Press the Valve Cotter Tool Kit - Assembly Cartridge -

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VAS5161/8A- onto the insertion device from above and cap‐

ot
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ture the valve retainers.

h re
hole
spec
– Press the Valve Cotter Tool Kit - Assembly Cartridge -

es, in part or in w
t to the co
VAS5161/8A- downward with the Valve Cotter Tool Kit - Pres‐

sure Fork with Lever for Assembly Cartridge - VAS5161/2- and
turn the assembly cartridge knurled screw back and forth while
rrectness of i
pulling it upward at the same time.

l purpos
– Release the Valve Cotter Tool Kit - Pressure Fork with Lever
for Assembly Cartridge - VAS5161/2- with the knurled screw
pulled.
nform
ercia
– Remove the Valve Cotter Tool Kit - VAS5161A- .

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3.5 Valve Guides, Checking

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♦ Dial Gauge Holder - VW387- ht. rig
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♦ Dial Gauge - 0-10mm - VAS6079- by c lksw
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3. Valvetrain 191
Test Sequence
– Insert the valve into guide. The valve stem end must be flush
with the guide. Due to the slight difference in stem diameters,
use only an intake valve in the intake guide and an exhaust
valve in the exhaust guide.
– Determine the tilting clearance.
Wear Limit
Intake Valve Guide Exhaust Valve Guide
0.80 mm 0.80 mm
Note
♦ If the wear limit is exceeded, measure again using new valves.

If the wear limit is still exceeded, replace the cylinder head.
♦ If the valve is to be replaced as part of a repair, use a new
valve for the measurement.
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4 Special Tools

equipment required
10-222A-
Sub-frame Adapter -
10-222A/22-
Engine Support 3 -
10-222A/10- quantity: 2
Shackle - 10-222A/12-
♦ For automatic transmis‐
AG. Volkswagen AG d
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4. Special Tools 193


10-222A-
with Spindle and Hook -
10-222A/10-
Shackle - 10-222A/12-
♦ Bits for VAG1331/13 -
T10099- agen
AG. Volkswagen AG d
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♦ Engine Support Bridge - ed by
V gu
ara
Gearbox Adapter - horis nte
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10-222A/13- aut ra
c
ss
ce
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un
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spec
t to the co
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cial p
f inform
mer
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♦ Spark Plug Removal Tool -

3122B-
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem
- 3365-
♦ Valve Cotter Tool Kit - AG. Volkswagen AG d
Adapter - T40012- agen oes
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♦ Torque Wrench 1331 orise nte
5-50Nm - VAG1331- auth eo
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♦ Valve Keeper Tool Kit -
ce
le
un
pt
VAS5161A- .
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♦ Valve Cotter Tool Kit -
rm
ab
pe
ility
Guide Plate 19C -
ot
wit
VAS5161/19C-
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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te o
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♦ Spark Plug Removal Tool -

3122B-
♦ Puller - Ignition Coil -
T40039-
5-50Nm - VAG1331-
. Volkswagen AG
gen AG does
♦ Compression Tester Kit - Vol
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VAG1763- ed
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♦ Compression TesterauKit
th - eo
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Adapter 5A - VAG1381/5A-
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un
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♦ Fuel Injection Gauge Kit -
an
d
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CO Adapter - VAG1381/1-
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5-50Nm - VAG1331-
40-200Nm - VAG1332-
VAS6122-
♦ Shop Crane - Drip Tray -
VAS6208-
♦ Polydrive Bit Drive Socket -
T10070-
AG. Volkswagen AG d
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♦ Central Valve Assembly

Tool - T10352-
♦ Central Valve Assembly
Tool - T10352/1-
♦ Counterhold - Vibration
Damper - T10355-
AG. Volkswagen AG d
♦ Locking Pin (3 pc.) - agen oes
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V
T40011- d by gu
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rise nte
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♦ Chain Tensioner Lever - auth eo
ra
T40243- ss c
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un
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♦ Tensioner Locking Tool -
an
d
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T40267-
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♦ Bits for VAG1331/13 - T10099-
♦ Dial Gauge Adapter - T10170A-
AG. Volkswagen AG d
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♦ Seal Installer - Selector Shaft Oil Seal - T10174-
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
r
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♦ Press Piece - Gearbox - T10375-
AG. Volkswagen AG d
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atio
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n
♦ Assembly Tool - Knurled Nut - T10531/4- from the Assembly
c
i
or
n
Tool - T10531-
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at
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io
♦ Engine Support Bridge - Engine Bracket - 10-222A/1- n
c
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ate
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AG. Volkswagen AG d
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CC 2010 ➤ , Eos d by 2006 ➤ , Golf 2004 ➤ , Golf 2009
V gu ➤ , Passat 2006 ➤ , ...
ara
e nte
4-CylinderthFuel
oris
Injection Engine (1.8L and 2.0L Engine, eChain
or
Drive) - Edition 07.2015
au ac
ss
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♦ Counterhold Tool - T10531/1-
♦ Tensioning Pins - T10531/2-
♦ Turning Over Tool - T10531/3-
♦ Knurled Nut - T10531/4-

17 – Lubrication
1 Oil Pan and Oil Pump
⇒ “1.1 Overview - Oil Pan and Oil Pump”, page 203 .
⇒ “1.2 Oil Separator, Removing and Installing”, page 206 .
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”,
agen
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⇒ “1.4 Oil Pump, Removing and Installing”,hopage
ris 209 . nte
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⇒ “1.5 Oil Pan Upper Section, Removing
ss and Installing”,
page 211 .
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1.1 Overview - Oil Pan and Oil Pump
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Note
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♦ If large quantities of metal shavings or abraded material are
t to the co
detected during engine repairs, it may mean the crankshaft or
connecting rod bearings are damaged. To prevent subsequent
damage, perform the following steps after the repair:
rrectness of i
♦ Clean the oil channels carefully.
l purpos
♦ Replace the oil spray jets.
nform
ercia
♦ Replace the engine oil cooler.

m
♦ Replace the oil filter.
a
com
tion in
♦ The oil level must not exceed the MAX marking - danger of
r
te o
thi
damaging the catalytic converter.
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1. Oil Pan and Oil Pump 203

1 - Oil Level Thermal Sensor -

G266-
❑ Not on engine codes
CBFA, CCTA and
CCTB
2 - Seal
❑ Always replace
3 - Bolt
❑ Always replace
Refer to
⇒ Fig. ““Oil Pan Lower
Section - Tightening Se‐
quence”“ , page 205
4 - Oil Pan Lower Section
ling. Refer to
⇒ “1.3 Oil Pan Lower
Section, Removing and
5 - Bolt
❑ 9 Nm
6 - Oil Baffle
❑ If the oil pan upper sec‐
tion is being replaced,
the oil baffle must also
be replaced
7 - Oil Pump Bolts
tion:
M6 = 9 Nm AG. Volkswagen AG d
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M8 = 20 Nm d by
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8 - Oil Pump aut
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❑ Removing and installing. Refer to ⇒ “1.4 Oil Pump, Removing and Installing”, page 209 .
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9 - Centering Bracket
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10 - Chain Tensioner
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11 - Bolt
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❑ 9 Nm
spec
es, in part or in w
12 - Bolt
t to the co
❑ 9 Nm
❑ Only engine codes CCZA, CCZB, CCZC, CCZD, CDAA and CDAB
rrectness of i
13 - Oil Pressure Regulation Valve - N428-

l purpos
nform
ercia
⇒ “1.6 Oil Pressure Regulation Valve N428 , Removing and Installing, Engine Codes CCZA, CCZB,
CCZC, CCZD, CDAA, and CDAB”, page 214 .
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14 - O-Ring
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❑ Always replace
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15 - Oil Pump Drive Chain

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❑ Mark direction of rotation before removing
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204
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Prote AG.
Rep. Gr.17 - Lubrication
16 - Seal
❑ Always replace
17 - Oil Separator
❑ Removing and installing. Refer to ⇒ “1.2 Oil Separator, Removing and Installing”, page 206 .
18 - Bolt
❑ Tightening sequence. Refer to ⇒ Fig. ““Oil Separator - Tightening Sequence”“ , page 206
19 - Oil Pan Upper Section
❑ Removing and installing. Refer to ⇒ “1.5 Oil Pan Upper Section, Removing and Installing”, page 211 .
20 - Bolt
❑ 9 Nm
21 - Bolt
❑ Always replace
. Volkswagen AG
❑ Tightening sequence. Refer to ⇒ Fig. ““Oil gen AG
aPan Upper Section d-oTightening
es n Sequence”“ , page 206
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22 - Oil Intake Pipe ris
ed
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o
❑ Clean the strainer if it is dirty.
au
th or
ac
ss
23 - O-Ring
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❑ Always replace
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24 - O-Ring
ility
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❑ Always replace
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hole
25 - O-Ring
spec
es, in part or in w
❑ Always replace
t to the co
26 - Check Valve
27 - Oil Drain Plug
rrectness of i
❑ 30 Nm
l purpos
❑ Always replace
28 - Nut
nf
ercia
❑ 9 Nm orm
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atio
om
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or c
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Oil Pan Lower Section - Tightening Sequence

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– Tighten the bolts -1 through 20- in three steps as follows:

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2- Tighten the Bolts to 8 Nm py by
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3- Turn the Bolts an Additional 45°
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Prote AG.

Oil Pan Upper Section - Tightening Sequence

– Tighten the bolts -1 through 14- in three steps as follows:
1- Tighten Bolts Hand-Tight
2- Tighten the Bolts to 15 Nm
3- Tighten the Bolts an Additional 90°
Oil Separator - Tightening Sequence

– Tighten the bolts to 9 Nm in the sequence -1 to 9-.
AG. Volkswagen AG d
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1.2 Oil Separator, Removing and Installing
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Gr. 50 ; Noise Insulation . rrectne
– Remove the bolts -1 through 9- and remove the oil separator.

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Risk of contaminating the lubricating system.

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♦ Seal the opening with a clean cloth.

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♦ Replace the gaskets and seals.
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♦ Secure all hose connections with hose clamps appropriate for

the model. Refer to the Parts Catalog.
Install in reverse order of removal. Note the following:
206 Rep. Gr.17 - Lubrication

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– Tighten the bolts to 9 Nm in thebsequence
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1.3 Oil Pan Lower Section, Removing and
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Installing
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♦ Used Oil Collection and Extraction Unit - SMN372500-
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♦ Hand Drill with Plastic Brush Attachment

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♦ Flat-Blade Scraper
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♦ Commercially available scraper

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♦ Protective Eyewear
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Removing
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– If equipped, disconnect the connector -1- for the Oil Level
Thermal Sensor - G266- .
Note
Observe the disposal regulations!


– Carefully loosen the oil pan lower section from the bonding
using a commercially available scraper.
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– Remove the lower oil pan Vol section, and if necessary loosen
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♦ The oil pan must be installed within five minutes after appli‐
t to the co
cation of silicone sealant.
rrectness of i
– Remove sealant residue from upper section of the oil pan with
a flat-blade scraper.
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WARNING
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Risk of eye injury.
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♦ Wear protective eyewear!

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– Remove any remaining sealant from the oil pan lower section
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using, for example, a rotating plastic brush. Cop py
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proximately 3 mm).

– Apply the Silicone-Sealant - D 174 003 A2- onto the clean

sealing surface of the oil pan lower section as shown.
Note
♦ The oil pan must be installed within five minutes after appli‐
cation of silicone sealant.
pipe screen.
– Immediately mount the oil pan lower section and tighten the
bolts -1 through 20- in three stages as follows:
1- Tighten Bolts Hand-Tight.
2- Tighten the Bolts to 8 Nm.
3- Turn the Bolts an Additional 45°
Note
After installing the oil pan, allow the sealant to dry for approxi‐
mately 30 minutes. Only after then may the engine oil be replen‐
ished.
– Fill the engine oil. Oil capacities: Refer to

⇒ “2 Engine Oil”, page 216 .
AG. Volkswagen AG d
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Oil Pump, Removing and Installing
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Special tools
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♦ Elbow Assembly Tool - T10118-
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♦ Chain Tensioner Locking Tool - T40265-

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Removing:
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– Remove the oil pan lower section. Refer to

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⇒ “1.3 Oil Pan Lower Section, Removing and Installing”, page

ole,
spec
207 .
t to the co
– Remove the oil baffle -arrows-.

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– Pull the chain tensioner spring using the Elbow Assembly Tool
- T10118- in direction of -arrow- and secure it with the Chain
Tensioner Locking Tool - T40265- .
– Remove the bolts -arrows- and remove the oil pump.
AG. Volkswagen AG d
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Engine Codes CBFA and CCTA:

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Installing:
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– Make sure there are both alignment bushings for centering the
spec
oil pump.
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– Check the oil intake pipe screen and the oil channels in the oil
pan upper section for contamination before installing the oil
pump.
rrectne
– Guide the oil pump chain sprocket into the drive chain and
install the oil pump.
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Caution
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There is a risk of destroying the engine.

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♦ The following procedure must be observed otherwise the

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chain tensioner spring will not spring into the installation

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position:
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– Pull the chain tensioner spring with the Elbow Assembly Tool
- T10118- in the direction of -arrow- and remove the Chain
Tensioner Locking Tool - T40265- .
The rest of the installation is performed in reverse order of re‐
moval, while doing so pay attention to the following:
Tightening specifications. Refer to
1.5 Oil Pan Upper Section, Removing and

Installing lkswagen AG. Volkswagen AG does n
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♦ Elbow Assembly
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If the oil pan upper section is being replaced, the oil baffle
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-item 6- ⇒ Item 6 (page 204) must also be replaced
Removing
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– Remove the oil pump. Refer to

⇒ “1.4 Oil Pump, Removing and Installing”, page 209 .
nform
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– Remove the transmission side sealing flange. Refer to

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⇒ “2.4 Transmission-Side Sealing Flange, Removing and In‐

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– Remove the right wheel housing liner front section. Refer to ⇒

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Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front

p
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Wheel Housing Liner, Removing and Installing .

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– Remove the bolts -arrows-. C py
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– Open the clamps -1 and 2- and remove the air guide pipe. op Vo
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– Remove the screw -1-.
AG.

– Remove the wiring bracket mount next to the After-Run Cool‐

ant Pump - V51- from the oil pan upper section.
DANGER!
Risk of injury! When removing the oil pan upper section, the
chain tensioner spring for the oil pump motor will jump from the
oil pan upper section to the lower timing chain cover. When
removing the oil pan upper section, do not reach between the
section and the lower timing chain cover.
– Remove the bolts -1 through 14- and pry out the oil pan upper
section.
Caution
First pry the oil pan upper section out on the transmission side.
When prying out, be careful not to bend the timing chain cover.
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• Tightening specification. Refer to ss
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Note
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♦ The oil pan upper section must be installed within five minutes
es, in part or in w
t to the co
of applying the silicone sealant.
– Remove the sealant residue from cylinder block with a flat-

rrectness of i
blade scraper.
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WARNING
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Risk of eye injury.

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♦ Wear protective eyewear!

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– Remove the remaining sealant on the oil pan upper section

and on the lower timing chain cover, for example with a rotating
plastic brush.
Note
See if the timing chain cover is deformed. Then mount the oil pan
upper section without any sealant and check the gap between the
cover and the oil pan upper section. If a deformation is found and
the cover cannot be aligned, replace the cover after installing the
oil pan upper section.

grease.
– Make sure the oil channels in the oil pan upper section and in
the cylinder crankcase are clean.
– Cut the tube nozzle at the front marking (nozzle diameter:

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Caution au
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There is a risk that the lubrication system could be blocked by
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excess sealant! Do not apply sealant bead thicker than indi‐

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– Apply the Silicone-Sealant - D 174 003 A2- onto the clean
sealing surface of the oil pan upper section as shown
rrectness of i
-arrow-.
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– Also apply some Silicone-Sealant - D 174 003 A2- between

the cylinder block and the timing chain cover -arrows-.
• Sealant bead thickness: 2 to 3 mm.
Note
♦ The oil pan upper section must be installed within five minutes
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pipe screen. ss c
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• On the transmission side, the oil pan upper section and the
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crankcase must align.
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– Immediately mount the oil pan upper section and tighten the
bolts -1 through 14- in three steps as follows:
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1- Tighten Bolts Hand-Tight.
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2- Tighten the Bolts to 15 Nm.

3- Tighten the Bolts an Additional 90°.
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– Install the bolts -arrows-.
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Tightening sequence for the cover with 15 bolts. Refer to

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⇒ Fig. ““Lower Timing Chain Cover - Tightening Sequence for 15

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Bolts”“ , page 90
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Tightening sequence for the cover with 8 bolts. Refer to
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⇒ Fig. ““Lower Timing Chain Cover - Tightening Sequence for 8

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Bolts”“ , page 91 Cop py
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1.6 Oil Pressure Regulation Valve - N428- ,

Removing and Installing, Engine Codes
CCZA, CCZB, CCZC, CCZD, CDAA,
and CDAB
♦ Used Oil Collection and Extraction Unit - SMN372500-
Removing:

– Place the Used Oil Collection and Extraction Unit -

SMN372500- under the engine.
– Remove the bolt -2- and the Oil Pressure Regulation Valve -
N428- -3-.
Installing:
AG. Volkswagen AG d
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olksw not
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AG. Volkswagen G d
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agen Engine (1.8L Aand oe2.0L
s n Engine, Chain Drive) - Edition 07.2015
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2 Engine
s
Oil au
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Oil Capacities:
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Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
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The oil capacity it determined by attempting. For reasons of tol‐
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erance, the oil temperature and dripping time can cause variance
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in the actual oil capacity. The performed repair influences the oil
hole
spec
capacity. The measurement for the correct oil level is the mark on
es, in part or in w
the oil dipstick guide tube.
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Engine oil specification. Refer to ⇒ Fluid Capacity Tables; Rep.
Gr. 03 .
rrectness of i
Always replace the engine oil. Refer to ⇒ Maintenance ; Booklet
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24.1 ; Procedure Descriptions; Engine Oil, Draining or Extracting,

Changing Oil Filter and Filling Oil .
nform
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Checking the Oil Level:

m
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Note
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The oil level must not exceed the MAX marking - danger of dam‐
p
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Test Conditions
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• The engine oil temperature must be at least 60 °C (140 °F).
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• Vehicle must be at a level position.
• After stopping engine, wait a few minutes to allow oil to flow
back into oil pan.
Test Sequence
– Pull out the oil dipstick, wipe off with a clean cloth and insert it
all the way.
– Withdraw dipstick again and check the oil level.
Range of markings on dipstick:
a - Oil must not be added.
b - Oil may be added.
c - Oil must be added.
Note
Oil level must not exceed the MAX mark -arrow 1- and must not
fall short of the MIN mark -arrow 2-.

3 Oil Filter, Engine Oil Cooler and Oil

Pressure Switch, Engine Codes
⇒ “3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure
Switch F1 ”, page 217 .
⇒ “3.2 Engine Oil Cooler, Removing and Installing”, page 218 .
⇒ “3.3 Oil Pressure and Oil Pressure Switch, Checking”,
page 219 .
3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure Switch - F1-
ling. Refer to
⇒ “1.6 Sub-Assembly
Bracket, Removing and
2 - Oil Pressure Switch - F1-
❑ 20 Nm
AG. Volkswagen AG d
❑ Remove using the ksw
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Socket and Jointed Ex‐ byV
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tension - 24mm - rised
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T40175- aut
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❑ 1.4 bar (20.30 psi) - s
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⇒ “3.3 Oil Pressure and
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Oil Pressure Switch,
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3 - Seal
spec
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❑ Always replace
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4 - O-Ring
❑ Always replace
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5 - O-Ring
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❑ Always replace
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6 - Valve Unit
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7 - Oil Filter
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❑ 22 Nm
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❑ Remove and install us‐

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ing the Wrench - Oil Fil‐

p
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ter - 3417-
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8 - Bolt Cop py
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9 - Connection
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10 - Seal
❑ Always replace
11 - Engine Oil Cooler
❑ See note. Refer to ⇒ “1 Oil Pan and Oil Pump”, page 203 .
❑ Make sure there is enough space to the surrounding components
❑ Coolant Hose Connection Diagram. Refer to ⇒ “1.1 Coolant Hose Connection Diagram”, page 231 .
❑ Removing and installing. Refer to ⇒ “3.2 Engine Oil Cooler, Removing and Installing”, page 218 .
3. Oil Filter, Engine Oil Cooler and Oil Pressure Switch, Engine Codes 217
12 - Seal
❑ Always replace
13 - Bolt
3.2 Engine Oil Cooler, Removing and Instal‐

ling
Removing
Proceed as follows:
WARNING

warm.
cloth and carefully opening. agen
AG. Volkswagen AG d
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– Drain the coolant. Refer to tho or
⇒ “1.2 Coolant, Draining and Filling”, pagess233 . au ac
ce
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– Remove the sub-assembly bracket. Refer to
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⇒ “1.6 Sub-Assembly Bracket, Removing and Installing”, page
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– Remove the bolts -4 and 5- and remove the engine oil cooler
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-3- together with the seal -2-.
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Installing
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• Tightening specifications. Refer to rrectness of i
⇒ “3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure
Switch F1 ”, page 217 .
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Note
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at

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– Install the engine oil cooler -3- with a new seal -2-.
AG. Volkswagen AG d
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3.3 Oil Pressure and Oil Pressure Switch, d by
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Checking horise nte
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Special tools and workshop equipment required ss
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♦ Oil Pressure Gauge Kit - VAG1342-
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♦ Voltage Tester - VAS6839-
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♦ Connector Test Set - VAG1594D-
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♦ Socket and Jointed Extension - 24mm - T40175-
spec
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Conditions:
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• Engine oil level OK
• Engine oil temperature at least 80 °C (176 °F) (radiator fan
rrectness of i
must start up once).
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Note
nform
mercia
For the functional check and servicing of the optical and acoustic
at
om
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oil pressure warning: use the wiring diagrams. Refer to Vehicle
n
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Diagnostic Tester “Function and Component Selection”.

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Test Sequence
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3. Oil Filter, Engine Oil Cooler and Oil Pressure Switch, Engine Codes 219
– Remove the Oil Pressure Switch - F1- and install the oil pres‐
sure gauge in its place.
– Thread the oil pressure gauge into the oil filter bracket in place
of oil pressure switch.
– Connect brown wire on the tester to the ground (-).
– Connect the Voltage Tester - VAS6839- to battery positive (+)
and the oil pressure switch using adapter cables from the
Connector Test Set - VAG1594D- . LED must not light up.
– If the LED lights up, replace 1.4 bar (20.30 psi) Oil Pressure
Switch - F1- .
If the LED does not light up:
– Start the engine and increase the RPM: the LED must come
on at 1.2 to 1.6 bar (17.4 to 23.2 psi) pressure; if not, then
replace the oil pressure switch.
– Increase the RPM further.
• At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil
pressure must be between 2.0 and 4.5 bar (29 to 65.26 psi).
– Check the oil intake pipe screen for contamination -item 22-
⇒ Item 22 (page 205) .

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Also, mechanical damage, for example, d bearing damage can also
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be the cause of too low oil pressure.
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If no error can be found:
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– Replace the oil pump. Refer to

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If the specified value is exceeded:

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– Check the oil channels.

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spec
es, in part or in w
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mercia
at
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ion
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ate
do
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4 Oil Filter, Oil Cooler and Oil Pressure

Switch, Engine Codes CCZA, CCZB,
CCZC, CCZD, CDAA, and CDAB
⇒ “4.1 Overview - Oil Filter and Oil Cooler”, page 221 .
⇒ “4.2 Engine Oil Cooler, Removing and Installing”, page 222 .
⇒ “4.3 Oil Pressure Switch F1 , Removing and Installing”,
page 223 .
⇒ “4.4 Reduced Oil Pressure Switch F378 , Removing and In‐
stalling”, page 224olk. swage es n
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⇒ “4.5 Oil Pressure
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ed and Oil Pressure Switch, Checking”,
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tee
page 225uth.o or
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4.1 Overview - Oil Filter and Oil Cooler
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hole
⇒ “1.6 Sub-Assembly
spec
Bracket, Removing and
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t to the co
2 - Oil Pressure Switch - F1- rrectness of i
❑ Blue insulation
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ling. Refer to
⇒ “4.3 Oil Pressure
nf
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Switch F1 , Removing
or
and Installing”,
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atio
page 223 .
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❑ 20 Nm
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3 - Reduced Oil Pressure
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Switch - F378-
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❑ Brown insulation
ling. Refer to
⇒ “4.4 Reduced Oil
Pressure Switch F378 ,
ling”, page 224 .
❑ 20 Nm
4 - Seal
❑ Always replace
5 - O-Ring
❑ No replacement part, part of the valve unit delivery package
6 - O-Ring
❑ No replacement part, part of the valve unit delivery package
4. Oil Filter, Oil Cooler and Oil Pressure Switch, Engine Codes CCZA, CCZB, CCZC, CCZD, CDAA, and CDAB 221
7 - Valve Unit
❑ With O-rings
8 - Oil Filter
❑ Remove and install using the Wrench - Oil Filter - 3417-
9 - Bolt
❑ 15 Nm
10 - Connection
11 - Seal
❑ Always replace
❑ See note. Refer to ⇒ “1 Oil Pan and Oil Pump”, page 203 .
❑ Make sure there is enough space to the surrounding components
❑ Removing and installing. Refer to ⇒ “4.2 Engine Oil Cooler, Removing and Installing”, page 222 .
13 - Seal
❑ Always replace
14 - Bolt
4.2 Engine Oil Cooler, Removing and Instal‐

ling
Removing
WARNING
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The coolant system is under pressure when the engine is d by Vo ot g
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warm. o
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th or
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Risk of scalding due to hot steam and hot coolant. ss
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– Remove the sub-assembly bracket. Refer to

es, in part or in w
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52 .
rrectness of i
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Rep. Gr.17 - Lubrication
4-Cylinder Fuel Injection Engine (1.8L and 2.0L Engine,geChain Drive)
n AG. Volkswage-nEdition
AG d 07.2015
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– Remove the bolts -4 and 5- and remove the engine oil icooler
ed
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-3- together with the seal -2-. tho eo
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Installing ss
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Note
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– Install the engine oil cooler -3- with a new seal -2-.
nform
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– Install the sub-assembly bracket. Refer to

m
at
om
io
52 .
n
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– Fill with coolant. Refer to

at
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4.3 Oil Pressure Switch - F1- , Removing

and Installing
Removing
– Vehicles with sound generator: open the locking mechanism
-1-, unclip the fuel lines -2- and loosen the bolt -3- on the EVAP
canister. Move the charge air pipe aside.
– Disconnect the vent line -1-, unlock the EVAP canister -A- and
remove it upward -B-. Move the EVAP canister to the side.
Note
Place a cloth under the sub-assembly bracket to collect leaking

engine oil.
– Disconnect the connector -4- from the Oil Pressure Switch -

F1- .
– Remove the Oil Pressure Switch - F1- -3-.
Installing
♦ Replace the seal.
♦ To prevent coolant loss, insert the new Oil Pressure Switch -
F1- in the hole immediately.
♦ Check the oil level.
4.4 Reduced Oil Pressure Switch - F378- ,

Removing n AG. Volkswagen AG do
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– Vehicles with sound generator: open d the locking mechanism
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-1-, unclip the fuel lines -2- and loosen
tho the bolt -3- on the EVAP tee
or
canister. Move the charge airs apipe
u aside. ac
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Rep. Gr.17 - Lubrication Prote AG.
Note

engine oil.
– Disconnect the connector -2- from the Reduced Oil Pressure

Switch - F378- .
– Remove the Reduced Oil Pressure Switch - F378- -1-.
Installing
AG. Volkswagen AG d
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♦ Replace the seal. olksw
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♦ To prevent coolantoris loss, insert the new Reduced Oil Pressure
e nte
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Switch - F378-aut in the hole immediately.
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♦ Check the oil level.
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4.5 Oil Pressure and Oil Pressure Switch,

erm
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Checking
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es, in part or in w
♦ Oil Pressure Gauge Kit - VAG1342-

t to the co
♦ Voltage Tester VAS6839 - VAS6839-

♦ Connector Test Set - VAG1594D-
rrectness of i

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Conditions:
nf
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• Engine oil level OK

orm
m
atio
• Engine oil temperature at least 80 °C (176 °F) (radiator fan

om
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must start up once).

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Oil Pressure, Checking: n AG. Volkswagen AG do

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– Vehicles with sound generator: open the locking mechanism byV
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-1-, unclip the fuel line -2- and loosen the bolt -3-
ir seon the EVAP
d ran
tee
canister. Move the charge air pipe aside. au tho
or
ac
ss
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un
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Note
nform
mercia
a
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tio
engine oil.
n in
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– Disconnect the connector -2- from the Reduced Oil Pressure

Switch - F378- (brown).
– Remove the Reduced Oil Pressure Switch - F378- -1-.
– Install the Oil Pressure Gauge Kit - VAG1342- into the oil filter
bracket in place of the oil pressure switch.
– Install the Reduced Oil Pressure Switch - F378- in the Oil
Pressure Gauge Kit - VAG1342- .
– Connect the charge air pipe and EVAP canister vent line.
– Start the engine.
• Oil pressure when the vehicle is idling: 1.2 to 2.1 bar (17.4 to
30.45 psi)
• Oil pressure at 2000 RPM: 1.6 to 2.1 bar (23.2 to 30.45 psi).
• Oil pressure at 3700 RPM: 3.0 to 4.0 bar (43.5 to 58 psi)
Note
The oil pressure may be 3.0 to 4.0 bar (43.5 to 58 psi) at 2,000
RPM during the first 1,000 km.

– Check the oil intake pipe screen for contamination -item 22-
⇒ Item 22 (page 205) .
– Check the Oil Pressure Regulation Valve - N428- . Refer to
Vehicle DiagnosticagTester
en AG. V.
olkswagen AG
d
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Note ris
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Also, mechanical damage, for example, bearing damage can also
ce
le
un
pt
be the cause of too low oil pressure.

an
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pe

ility
ot
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– Replace the oil pump. Refer to

h re

hole
spec
es, in part or in w
Checking the Reduced Oil Pressure Switch - F378- (brown):

t to the co
– Turn off the engine.

rrectness of i
l purpos
nform
mercia
a
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tion in
r
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thi
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Prote AG.
– Connect brown wire on the tester to the ground (-).

– Connect the Voltage Tester - VAS6839- with adapter cables
from the Connector Test Set - VAG1594D- to the battery pos‐
itive (+) and the Reduced Oil Pressure Switch - F378- (brown).
• LED must not light up.
– If the LED illuminates, replace the Reduced Oil Pressure
Switch - F378- .
– Start the engine: the LED must come on at 0.55 to 0.85 bar
(7.97 to 12.32 psi). If it does not, replace the oil pressure
switch.
Oil Pressure Switch - F1- (blue), checking:
– Turn off the engine.
– Connect the Voltage Tester - VAS6839- to battery positive (+)
and the Oil Pressure Switch - F1- (blue) using the adapter ca‐
bles from the Connector Test Set - VAG1594D- .
• LED must not light up.
– If the LED illuminates, replace the Oil Pressure Switch - F1- .
– Start the engine and increase the RPM: the LED must come agen
AG. Volkswagen AG d
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on at 2.15 to 2.95 bar (31.18 to 42.78 psi) pressure;y Vifonot, not
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replace the oil pressure switch. ised b ara
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5 Special Tools

equipment required
♦ Oil Pressure Gauge Kit -
VAG1342-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set -
VAG1594D-
♦ Socket and Jointed Exten‐
sion - 24mm - T40175-
AG. Volkswagen AG d
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ion
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ate
do
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♦ Used Oil Collection and Extraction Unit - SMN372500- gh ht
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19 – Cooling System
1 Cooling System
⇒ “1.1 Coolant Hose Connection Diagram”, page 231 .
⇒ “1.3 Coolant System, Checking for Leaks”, page 238 .
1.1 Coolant Hose Connection Diagram
WARNING

warm.

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♦ Secure all hose connectionsriswith
ed hose clamps appropriate for
b ran
tee
the model. Refer to the Parts
uth Catalog.
o
or
s a ac
♦ The arrows on coolant pipes and ends of coolant hoses must
s
ce
le
align when installing.

un
pt
an
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ab
Vehicles with Manual Transmission ility
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1. Cooling System 231

1 - Radiator
2 - After-Run Coolant Pump -
V51-
3 - Coolant Pump
4 - Coolant Thermostat
6 - Cylinder Head and Cylinder
Block
7 - Turbocharger
8 - Coolant Expansion Tank
❑ With cap
❑ Pressure relief valve in‐
side cap, checking. Re‐
fer to
⇒ “1.3 Coolant System,
Checking for Leaks”,
page 238 .
9 - To Auxiliary Heater
10 - From the Auxiliary Heater
11 - Heater Core for the Heater
12 - Coolant Connection
AG. Volkswagen AG d
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c
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232 Rep. Gr.19 - Cooling System

1 - Radiator
V51-
3 - Coolant Thermostat
4 - Coolant Pump
6 - Cylinder Head and Cylinder
Block
7 - Turbocharger
8 - Coolant Expansion Tank
❑ With cap
❑ Pressure relief valve in‐
side cap, checking. Re‐
fer to AG. Volkswagen AG d
⇒ “1.3 Coolant System, lksw
agen oes
not
Checking for Leaks”,
d by Vo gu
ara
page 238 . orise nte
h eo
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9 - To AuxiliaryssHeater
a c
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nl
10 - From the Auxiliary Heater
pt
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11 - Heater Core for the Heater
erm
ab
ility
ot p
12 - Transmission Fluid Cooler
wit
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13 - Coolant Connection
hole
14 - Coolant Thermostat for the spec

es, in part or in w
t to the co
Transmission Fluid Cooler
❑ On some vehicles, the
thermostat is located on
rrectness of i
the outflow side of the

transmission oil cooler.
l purpos
nform
mercia
at
om
1.2 Coolant, Draining and Filling

ion
c
in t
or
his
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at
do
priv
♦ Cooling System Tester - Adapter - VAG1274/8-

um
for
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♦ Hose Clip Pliers - VAS6362-
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♦ Cooling System Charge Kit - VAS6096-
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Prote AG.
♦ Refractometer - T10007A-
Draining
WARNING

warm.


Passat, CC, Golf, and Eos:
– Remove the air guide hose -1 and 2- and seal the charge air
cooler with a clean cloth. agen
AG. Volkswagen AG d
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– Place the Shop Crane - Drip Tray - VAS6208- under the en‐ ed by gu
ara
gine. horis nte
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aut ra
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un
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ility
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– Remove the lower coolant hose -1- from the radiator and let
es, in part or in w
the coolant drain.
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
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s
iva
do
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– Remove the lower coolant hose to the After-Run Coolant
fo
en
g
Pump - V51- -arrow- and allow the coolant to drain.

n
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Note
The After-Run Coolant Pump - V51- stays in the installed position.
Pump - V51- .

– Remove the coolant hose -1-.
– Remove the lower coolant hose to the After-Run Coolant

Pump - V51- -arrow- and allow the coolant to drain.
Filling:
Caution
Only mix distilled water with coolant additives. Using distilled

water provides optimum corrosion protection.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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ility
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nf
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Note
♦ The mixture of the water used greatly influences the effective‐

ness of the coolant. The water quality to be used is based on
the contents, which can be specific to a country or even a re‐
gion. Distilled water fulfills all requirements. For this reason,
use distilled water when adding coolant or filling coolant for the
first time.
♦ Use only coolant additives listed. Refer to the Parts Catalog.
Other coolant additives may above all reduce the corrosion
protection effect significantly. The damage resulting from this
may lead to loss of coolant and consequently to severe engine
damage.
♦ Coolant with the correct mixture ratio prevents freezing and
corrosion damage and calcium deposits. Additionally, the boil‐
ing temperature will be raised. For this reason the cooling
system must be filled with coolant additive year-round.
♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy engine loads, particularly in
countries with tropical climates.
♦ The Refractometer - T10007A- MUST be used to determine
the current freeze protection value.
♦ Protection against frost must be assured down to minimum -25
°C (-13 °F) (in arctic climatic countries down to approximately
-36 (-32.8 °F) °C). The freeze protection may only be in‐ AG. Volkswagen AG d
creased, when stronger freeze protection is needed due to the olkswagen oes
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climate. But only down to -48 °C (-54 °F), otherwise the effec‐d by V gu
ara
tiveness of the coolant decreases. orise nte
e h
ut or
♦ The coolant concentration must not be reduced by adding
ss
a
wa‐ ac
ter even in warmer seasons and in warmer countries. The frost
ce
e
nl
pt
protection must be at least -25 °C (-13 °F).
du
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erm
♦ Read the freeze protection value on the scale for the coolant
ab
ility
additive that has been added.
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♦ The temperature on the Refractometer - T10007A- corre‐
h re
hole
sponds to the »freezing point«. At this temperature, ice crys‐
spec
tals may begin to form in the coolant.
es, in part or in w
t to the co
♦ Do not reuse coolant.
♦ Only use water/coolant additive to lubricate the coolant hoses.
rrectness of i
l purpos
Recommended Mixture Ratios:

Frost Protection Anti-Freeze Coolant Ad‐ Distilled
nform
ercia
to ditive 1) Water 1)
m
at
-25 °C (-13 °F) 40 % 3.2L 4.8L

om
ion
-36 °C (-32.8 °F) 50 % 4.0L 4.0L

c
in t
or
his
ate
1)
The amount of coolant may vary depending on vehicle equip‐
do
priv
ment.
um
for
en
ng
t.
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– Connect the lower coolant hose -1- to the radiator.
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– Install the air guide pipe.
– Connect the coolant hose to the After-Run Coolant Pump -

V51- -arrow-. . Volkswage n AG d n AG
oes wage
With Cooling System Charge Kit - VAS6096-
yV
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– Screw the Cooling System hTester
oris - Adapter - VAG1274/8- on‐ nte
eo
to the reservoir. aut ra
c
ss
– Fill the coolant circuit using Cooling System Charge Kit -
ce
le
un
pt
VAS6096- . Refer to Operating Instructions for Cooling Sys‐
an
d
itte
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tem Charge Kit VAS6096.
rm
ab
pe
ility
Without Cooling System Charge Kit - VAS6096- :
ot
wit
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h re
hole
spec
es, in part or in w
– Slowly fill the coolant up to the upper marking in the hatched
t to the co
area on the expansion tank.
– Close the reservoir.
rrectness of i
– Start engine and keep the engine at about 2000 RPM for ap‐
l purpos
proximately three minutes.

– Allow the engine to run until the Radiator Fan - V7- starts run‐ nform
ercia
ning.
m
a
com
tion in
WARNING
r
te o
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iva
do

r
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Reduce pressure by covering the coolant reservoir cap with a yri
p by
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Prote AG.
– Check the coolant level and fill if necessary. When engine is

warm, the coolant level must be at the top marking and when
the engine is cold, it must be in the middle of the hatched field.

1.3 Coolant System, Checking for Leaks

♦ Cooling System Tester - VAG1274B-
Test Conditions
• Engine at operating temperature
Test Sequence:
WARNING
The coolant system iswaunder

gen AG pressuren when
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Risk of scalding
ho
ris due to hot steam and hot coolant. tee
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Reduce spressure
s by covering the coolant reservoir cap with ca
cloth and carefully opening. ce
le
un
pt
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– Open the cap on the coolant reservoir.
ility
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– Install the Cooling System Tester - Adapter - VAG1274/8- in

h re
ole,
the coolant expansion tank.

spec
– Clamp the Adapter - VAG1274B/1- in the Cooling System

t to the co
Tester - Adapter - VAG1274/8- .

– Connect the Adapter - VAG1274B/1- to the Cooling System
rrectne
Tester - VAG1274B- using the hose provided.

– Generate a positive pressure of approximately 1.0 bar (14.5
s
psi) using the tester hand pump.

s o
cial p
f inform
mer
DANGER!
atio
om
n
c
Risk of scalding! The existing pressure must be reduced before

i
or
n thi
disconnecting the Cooling System Tester - VAG1274B- from

te
sd
a
the connecting hose or the Adapter - VAG1274B/1- . To do this,

iv
o
pr
press the pressure release valve on the Cooling System Tester

um
r
fo
en
ng
- VAG1274B- until the pressure gauge displays the value »0«.

t.
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If the pressure drops:
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Prote AG.
– Look for leaks and correct.
Checking the Pressure Relief Valve in the Cap:
– Install the cap in the Cooling System Tester - Adapter -
VAG1274/9- .
– Clamp the Adapter - VAG1274B/1- in the Cooling System
Tester - Adapter - VAG1274/9- .

– Connect the Adapter - VAG1274B/1- to the Cooling System

Tester - VAG1274B- using the hose provided.
– Operate the hand pump.
• The pressure release valve must open at 1.4 to 1.6 bar (20.30
to 23.20 psi).
AG. Volkswagen AG d
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2 Coolant Pump, Coolant Thermostat

and Coolant Pipes
⇒ “2.1 Overview - Coolant Pump and Coolant Thermostat”, page
240 .
⇒ “2.2 Coolant Pump, Removing and Installing”, page 242 .
page 244 . Volkswa AG. gen AG
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⇒ “2.9 Small Coolant Pipe, Removing and Installing”, page 256 .
t to the co
⇒ “2.10 Overview - After-Run Coolant Pump V51 ”, page 257 .
rrectness of i
⇒ “2.11 After-Run Coolant Pump V51 , Removing and Installing”,
page 258 .
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2.1 Overview - Coolant Pump and Coolant Thermostat
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1 - Bolt
❑ 9 Nm
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❑ 4 Nm
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6 - Baseplate
❑ Only with the bolted ver‐
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7 - Engine Coolant Tempera‐

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ture Sensor - G62- tion in

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❑ Always replace
9 - Coolant Pump
❑ Removing and installing. Refer to ⇒ “2.2 Coolant Pump, Removing and Installing”, page 242 .
❑ For a new coolant pump, remove the protective cap
10 - Seal
❑ Always replace
11 - Centering Pin
❑ Quantity: 2
12 - Toothed Belt
❑ For the coolant pump
⇒ “2.3 Coolant Pump Toothed Belt, Removing and Installing”, page 244 .
13 - Toothed Belt Guard
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 10 Nm + 90° (1/4) additional turn
❑ Left-hand thread
❑ Always replace
2. Coolant Pump, Coolant Thermostat and Coolant Pipes 241

16 - Toothed Belt Drive Gear

❑ Installed position: the collar on the drive wheel faces the transmission.
17 - Shaft Seal agen
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18 - Balance Shaft tho or
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19 - Coolant Thermostat s
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❑ Removing and installing. Refer to ⇒ “2.5 Coolant Thermostat, Removing and Installing”, page 246 .
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20 - Centering Pin
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21 - O-Ring
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22 - Connection
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2.2 Coolant Pump, Removing and Installing

Removing
Proceed as follows:
– Remove the small coolant pipe. Refer to
⇒ “2.9 Small Coolant Pipe, Removing and Installing”,
page 256 .

4-Cylinder Fuel Injection Engine (1.8L. Vand
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– Remove the nut -1-, bolt -2-, and the intake manifold support.
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l purpos
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nf
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orm
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Inserted version. Refer to ⇒ page 252 .
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Threaded version. Refer to ⇒ page 252 .

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Installing
Note
♦ Replace the seals and O-rings.

♦ Install the coolant pump without the engine coolant tempera‐
ture sensor. The engine coolant temperature sensor slightly
sticks out of the coolant pump making it difficult to install the
coolant pump.
– Coat the O-rings -4- with coolant.

– Make sure that both centering pins are installed in the cylinder
block if necessary insert.
– Install the connection piece -2- into the engine oil cooler -1-.
– First slide the coolant pump -3- onto the connecting piece and
then onto the centering pins in the cylinder block.
– Using a mirror, check if the coolant pump is »seated« correctly
on the centering pins.

– Tighten the bolts in the sequence -1 to 5-.
Note
If a new coolant pump was installed, then the protective cap

-arrow- must be removed.
– Install the Engine Coolant Temperature Sensor - G62- . Refer

to
⇒ “2.6 Engine Coolant Temperature Sensor G62 , Removing
Inserted version. Refer to ⇒ page 252 .
Threaded version. Refer to ⇒ page 252 .
The rest of the installation follows the reverse of the removal pro‐
cedures.
2.3 Coolant Pump Toothed Belt, Removing

and Installing
♦ Torque Wrench 1331 Insert - Ring Wrench - 12mm - T10360-
♦ Torque Wrench 1410 - VAG1410-
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– Remove the coolant hoses -1 and 2- and lay them aside.
– Pull out the Intake Manifold Runner Control Valve - N316-

-2- (2.0L engine) or unscrew it (1.8L engine) and lay it to the
side.
– Free up the wiring harness, pull it upward and secure it with
cable ties.
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using the Torque Wrench 1410 - VAG1410- and Torque
rrectness of i
Wrench 1331 Insert - Ring Wrench - 12mm - T10360- . Coun‐

terhold the top of the crankshaft vibration damper with a 24
l purpos
mm socket when doing this.

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⇒ “2.1 Overview - Coolant Pump and Coolant Thermostat”, page
240 .
2.4 Coolant Pump Drive Shaft Seal, Always

replace
♦ Seal Installer - Intermediate Shaft - T10353-

Procedure
Proceed as follows:
page 244 . agen
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• “Luftseite” or (“Outside”) -arrow- must be readable from the

outside.
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n
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shaft seal -1- and press it into the cylinder block all the way
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page 244 .
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2.5 Coolant Thermostat, Removing and In‐

stalling
Note
On vehicles with map controlled engine the coolant pump must

be removed in order to remove the Map Controlled Engine Cool‐
ing Thermostat - F265- (coolant thermostat). Refer to

♦ Hex Ball Socket - T10058-

Removing
Proceed as follows:
– Disengage the side clips -arrows- and remove the cover for
the air duct. wage
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– Disengage ed the wire retainers -arrows- to unclipranthe lower air
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rrectne
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– Free up the coolant hose -2- and the wiring harness -1-.
– Remove the bolt -arrow- and remove bracket.

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– Loosen the nut -2-, remove the bolt -1- and move the support
for the intake manifold to the right.
– Remove the oil separator. Refer to
⇒ “1.2 Oil Separator, Removing and Installing”, page 206 .
– Remove bolts -arrows- and remove the connection. For the
right bolt, the Hex Ball Socket - T10058- is useful.

– Remove the coolant thermostat.

Installing
⇒ “2.1 Overview - Coolant Pump and Coolant Thermostat”,
page 240 .
Install in reverse order of removal
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Replace the seals and the O-rings.
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– Clean the sealing surface on the O-ring.
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hole
spec
pump and move it slightly forward in direction of -arrow-.
es, in part or in w
t to the co
Note
rrectness of i
Depending on the version a coolant thermostat can be installed
l purpos
without a centering pin.
nform
ercia
– Carefully mount the connector -3-, while doing so, insert the
m
centering pin -2- into the guide -1-.
at
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2.6 Engine Coolant Temperature Sensor -

G62- , Removing and Installing
Removing
Proceed as follows:
• The engine is cold.

the air duct.
– Disengage the wire retainers -arrows- to unclip the lower air
duct.
Refer to
All:

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cooler with a clean cloth.

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rrectness of i
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Engine Coolant Temperature
tho
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Sensor - G62- with Clip: eo
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– Disconnect the connector -1- on the Engine Coolant Temper‐ c
ss
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ature Sensor - G62- .
un
pt
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– Press the locking mechanisms in direction of -arrows- and re‐
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move the clip.
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To prevent a lot of coolant loss, immediately insert the new Engine
Coolant Temperature Sensor - G62- with an O-ring in the con‐
rrectne
nection.
ss
Engine Coolant Temperature Sensor - G62- with Retaining Plate:
o
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– Disconnect the connector -2- on the Engine Coolant Temper‐
mer
ature Sensor - G62- .
atio
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– Remove the bolts -arrows- and remove the retaining plate
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Installing:
♦ After the work is completed, check the coolant level.
2.7 Overview - Coolant Pipes

1 - Front Coolant Pipes

ling. Refer to
⇒ “2.8 Front Coolant
Pipes, Removing and
2 - Coolant Hose
❑ From the turbocharger
3 - Coolant Hose
❑ To the coolant expan‐
sion tank
4 - Bolt
❑ 3.5 Nm
5 - O-Ring
❑ Always replace
6 - Coolant Hose
❑ To the Heater Core for
the Heater
7 - Small Coolant Pipe
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11 - Coolant Hose
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❑ From the After-Run Coolant Pump - V51-

12 - Coolant Hose
rrectness of i
❑ To the After-Run Coolant Pump - V51-

l purpos
nform
2.8 Front Coolant Pipes, Removing and In‐

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stalling
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Removing
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WARNING

warm.

the air duct.
duct.
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Vehicles with Sound Generator: ss c
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– Open the latch -1-, unclip the fuel lines -2- and loosen the bolts
an
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-3-. Remove the charge air pipe.

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Vehicles with an EVAP Canister inside the Engine Compartment:

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es, in part or in w
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Rep. Gr.19 - Cooling System
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-arrow B-. Move the EVAP canister to the side.
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Gr. 50 ; Noise Insulation . auth eo
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– Place the Shop Crane - Drip Tray - VAS6208- under the en‐
gine.
– Remove the coolant hoses from the After-Run Coolant Pump
- V51- -arrows-.
AG. Volkswagen A
– Remove the bolts -1oland
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agen G do
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• Tightening
s
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– Assembly of hose connections with connection couplings. Re‐

l purpos
fer to
⇒ “1.2 Hose Connections with Connector Couplings, Assem‐
nf
ercia
bling”, page 426 .

orm
m
atio
m
2.9 Small Coolant Pipe, Removing and In‐

o
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or c
stalling
thi
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Removing
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page 465 .
Refer to

All:
AG. Volkswagen AG d
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– Remove the bolt -4-. Volksw
oes
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– Disconnect the connector oris -arrow-.
e nte
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ut ra
– Remove the bolt -1-ssand remove the air guide pipe downward.
a c
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un
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ility
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wit
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spec
– Remove the bolts -arrows- and remove the connectors
t to the co
-1 through 3- from the bracket.
– Free up the wiring harness on the small coolant pipe -arrow-.
rrectne
– Remove the bolts -2 and 3-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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– Disconnect the small coolant pipe from the coolant pump and
fo
en
ng
from the coolant hoses -1 and 4-.

t.
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Cop py
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Installing opyri
gh by
Vo
ht
by c
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Prote
AG.
Note
Secure all hose connections with hose clamps appropriate for the
model. Refer to the Parts Catalog.
– Assembly of hose connections with connection couplings. Re‐

fer to
2.10 Overview - After-Run Coolant Pump - V51-

1 - Bracket
2 - Bolt
❑ 40 Nm
3 - Coolant Hose
4 - Coolant Hose
V51-
6 - Bracket
7 - Bolt
❑ 8 Nm
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2.11 After-Run Coolant Pump - V51- , Re‐ au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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♦ Hose Clamps - Up To 25 mm - 3094-

wit
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hole
spec
Removing
es, in part or in w
t to the co
Proceed as follows:
rrectness of i
WARNING
l purpos

warm.
nf
ercia

rm
m
atio
m

o
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c

or
thi
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f
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t.
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258
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Rep. Gr.19 - Cooling System

Gr. 50 ; Noise Insulation . n AG. Volkswagen A ge G do
swa es
– Disconnect the connector
by
Vol -1- for the After-Run Coolant
k not
Pump
gu
ara
- V51- . ris
ed
nte
tho eo
– Place the Shop
ss
au Crane - Drip Tray - VAS6208- under the en‐ ra
c
gine.
ce
le
un
pt
an
– Disconnect the coolant hoses -arrows- with the Hose Clamps
d
itte
y li
- Up To 25mm - 3094- .
erm
ab
ility
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– Remove the coolant hoses from the After-Run Coolant Pump
wit
is n
- V51- .
h re
ole,
spec
– Remove the bolt -2- and the After-Run Coolant Pump - V51- .
t to the co
Installing
⇒ “2.10 Overview - After-Run Coolant Pump V51 ”,
rrectne
page 257 .
s
s o
cial p
f i
– Check the coolant level.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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3 Radiator and Radiator Fan

⇒ “3.1 Overview - Radiator, Fan Shroud and Radiator Fan, Pas‐
sat, CC, Golf, and Eos”, page 260 .
⇒ “3.2 Radiator Identification Sensor G611 , Installing ”,
page 261
⇒ “3.3 Overview - Radiator, Fan Shroud and Radiator Fan, Ti‐
guan”, page 262 .
⇒ “3.4 Fan Shroud, Removing and Installing”, page 263 .
⇒ “3.5 Radiator Fan V7 and Radiator Fan 2 V177 , Removing and
⇒ “3.6 Radiator, Passat, CC, Golf, and Eos, Removing and In‐
⇒ “3.7 Radiator, Removing and Installing, Tiguan”, page 266 .
3.1 Overview - Radiator, Fan Shroud and Radiator Fan, Passat, CC, Golf, and
Eos
1 - Radiator Fan - V7- AG. Volkswagen AG d

agen oes
❑ Removing and instal‐ Volksw not
gu
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ling. Refer to d b ara
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⇒ “3.5 Radiator Fan V7 thor eo
and Radiator Fan 2 ss au ra
c
V177 , Removing and
ce
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un

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2 - Nut
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❑ 10 Nm
ot
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3 - Fan Shroud h re
hole
spec
4 - Lower Coolant Hose
es, in part or in w
t to the co
❑ To the connection for

the coolant thermostat
5 - Clip
rrectness of i
6 - Engine Coolant Tempera‐

l purpos
ture Sensor on Radiator Outlet

- G83-
nform
ercia
7 - O-Ring
m
a
com
ion in
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8 - Upper Coolant Hose

thi
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❑ From the coolant pump

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10 - Bolt cop Vo
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❑ 5 Nm Prote AG.
❑ On the charge air cooler

11 - Radiator
ling. Refer to
⇒ “3.6 Radiator, Passat,
CC, Golf, and Eos, Re‐
moving and Installing”, page 265 .
❑ Engine code CBFA: with Radiator Identification Sensor - G611- . Refer to
⇒ “3.2 Radiator Identification Sensor G611 , Installing ”, page 261 .

olkswagen AG
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does07.2015
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12 - Nut ris
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❑ 10 Nm au ra
c
ss
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13 - Bolt
un
pt
an
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❑ 5 Nm
itte
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❑ On the radiator
pe
ility
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14 - Radiator Fan 2 - V177-
, is n
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spec
⇒ “3.5 Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing”, page 265 .
es, in part or in w
t to the co
3.2 Radiator Identification Sensor - G611- ,
rrectness of i
Installing
l purpos
nform
ercia
Note
m
a
com
t
♦ The Radiator Identification Sensor - G611- can be replaced
ion in
only together with the radiator.
r
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thi
s
iva
♦ Depending on the version, the Radiator Identification Sensor
do
r
rp
c
- G611- installation position can vary.
um
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Installing: C py
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– Coat the cylindrical part of the new sensor -arrow- with two cop Vo
by lksw
grams of Adhesive - AMV 195 KD1 01- . cted agen
Prote AG.
– Press the new sensor into the mount on the radiator until it
engages.
Lower Installation Position:

The -arrow- points in the direction of travel
-A- Radiator
-B- Radiator Identification Sensor - G611-
3. Radiator and Radiator Fan 261

Upper Installation Position:

The -arrow- points in the direction of travel
-1- Radiator
-2- Radiator Identification Sensor - G611-
AG. Volkswagen AG d
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3.3 Overview - Radiator, Fan Shroud and Radiator Fan, Tiguan ss aut ra
c
ce
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nl
pt
du
an
1 - Radiator
itte
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ab
ility
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ling. Refer to
wit
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⇒ “3.7 Radiator, Remov‐
h re
ing and Installing, Ti‐
hole
spec
guan”, page 266 .
es, in part or in w
t to the co
2 - O-Ring
rrectness of i
3 - Connection
l purpos
❑ To remove, pull off re‐

taining clips
nform
ercia
4 - Spring Clamp
m
❑ Removing and installing

at
om
with Hose Clip Pliers - ion

c
in t
VAS6340-
or
his
ate
do
riv
5 - Coolant Hose
p
cum
or
❑ Coolant Hose Connec‐

f
en
ng
t.
tion Diagram. Refer to
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Connection Diagram”, yri
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6 - Upper Coolant Hose
❑ To the Connection on
the Cylinder Head
❑ Coolant Hose Connec‐
tion Diagram. Refer to
⇒ “1.1 Coolant Hose
Connection Diagram”,
page 231 .
7 - Expansion Tank
❑ Perform a leak test for
the coolant system us‐
ing the Cooling System
Tester - VAG1274B-
and Cooling System Tester - Adapter - VAG1274/8- .
8 - Connector
9 - Cap
❑ Check using Cooling System Tester - VAG1274B- and Cooling System Tester - Adapter - VAG1274/9-
❑ The pressure release valve must open at a pressure of 1.4 to 1.6 bar (20.30 to 23.20 psi)

10 - Bolt
❑ 5 Nm
11 - Plastic Inserts
❑ For bolts
wage es n
12 - Bracket yV
olks ot g
ua
d b ran
13 - Air Shroud ir se tee
tho
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a ac
14 - Bolt ss
ce
le
❑ 5 Nm un
pt
an
d
itte
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15 - Radiator Fan 2 - V177-
rm
ab
pe
ility
ot
wit
⇒ “3.5 Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing”, page 265 .
, is n
h re
hole
16 - Connector
spec
es, in part or in w
17 - Radiator Fan - V7-
t to the co
❑ With Radiator Fan Control Module - J293-
18 - Bracket
rrectness of i
❑ For connector
l purpos
19 - Clip
nform
ercia

m
❑ To the connection for the coolant thermostat
a
com
tio
n in
r
te o
thi
21 - Engine Coolant Temperature Sensor on Radiator Outlet - G83-
s
iva
do
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rp
cum
fo
en
ng
t.
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❑ To the connection for the coolant thermostat
Co
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23 - Connection
by lksw
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❑ To remove, pull off retaining clips
24 - Nuts
❑ 10 Nm
3.4 Fan Shroud, Removing and Installing

Removing
the air duct.


duct.
– Remove the bolts -1- from the top.
Note
The left bolt is under the coolant connector.

Tiguan
olkswagen AG
en AG. V
– Remove the bracket -1-olby
kswremoving the bolts -arrows-.
ag does
not
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All rise nte
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– Disconnect sthe
s connector -2-. au ra
c
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nl
pt
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itte
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove the bolts -3- and remove the fan shroud downward.
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
t. rig
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Vo
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Prote AG.

– Cover the radiator with Protective Mat - VAS531003- .

Installing
♦ Install the fan shroud from underneath.
⇒ “3.1 Overview - Radiator, Fan Shroud and Radiator Fan,
Passat, CC, Golf, and Eos”, page 260 .
3.5 Radiator Fan - V7- and Radiator Fan 2 -

V177- , Removing and Installing
Removing
Proceed as follows:
– Remove the fan shroud. Refer to
– Free up the electric wires.
– Remove the nuts -arrows- and remove the radiator fan.
Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
s c
3.6 s
Radiator, Passat, CC, Golf, and Eos,
ce
le
un
pt

an
d
itte
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rm
ab
Removing
pe
ility
ot
wit
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Proceed as follows:
h re
hole

spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
fo
en
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
265
Prote AG.
3. Radiator and Radiator Fan
– Remove the upper coolant hose -arrow- from the radiator.
– Detach the air duct at the lock carrier -arrows- and remove the
air duct.
– Engine code CBFA: disconnect the Radiator Identification
Sensor - G611- connector. agen
AG. Volkswagen AG d
o
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Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
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un
pt
an
d
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erm
ab
ility
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ole,
spec
– Remove the bolts -1 and 2- and remove the radiator upward.
t to the co
Installing
rrectne
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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3.7 Radiator, Removing and Installing, Ti‐

en
ng
t.
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op
guan
C py
t. rig
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Vo
Removing
co lksw
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Proceed as follows:

– Remove the air guide hose -arrows- and seal the charge air
– Remove the bracket -1- by removing the bolts -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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ce
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un
pt
– Disengage the clamps and remove the connection -arrow- an
d
itte
from the radiator.

y li
rm
ab
pe
ility
– Likewise, disconnect the connection on the right radiator.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
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com
tion in
r
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thi
s
iva
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove the bolts -arrows- and remove the radiator down‐

ward.
Installing
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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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cum
fo
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t.
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Cop py
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by c lksw
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Prote AG.

4 Special Tools
Special tools and workshop . Volkswage

equipment requiredkswagen AG n AG d
oes
n ol ot g
yV ua
♦ Cooling System
ed
b Tester - ran
ris
Adapter
ut
ho - VAG1274/8- tee
or
sa ac
♦ Shop
s Crane - Drip Tray -
ce
e
VAS6208-
nl
pt
du
an
itte
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erm
ab
VAS6362-
ility
ot p
wit
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♦ Cooling System Charge Kit
h re
- VAS6096-
hole
spec
es, in part or in w
♦ Refractometer - T10007A-
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
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
♦ Hex Ball Socket - T10058-

♦ Seal Installer - Intermediate Shaft - T10353-
♦ Torque Wrench 1331 Insert - Ring Wrench - 12mm - T10360-
♦ Cooling System Tester - VAG1274B-
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
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erm
ab
ility
ot p
wit
, is n
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hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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t.
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co lksw
by
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♦ Torque Wrench 1410 - VAG1410-
AG. Volkswagen AG d
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ab
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♦ Hose Clamps - Up To 25mm - 3094-
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
♦ Protective Mat - VAS531003-
r
te o
thi
s
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cum
fo
en
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t.
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Cop py
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rig ht
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4-Cylinder Fuel Injection Engine (1.8L and 2.0L Engine, Chain eDrive) - Edition 07.2015
n AG. Volkswagen AG ag does
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ed
20 – Fuel Supply ris nte
tho eo
au ra
c
ss
ce
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nl
1 Safety Precautions
pt
du
an
itte
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erm
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ility
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1.1 Safety Precautions when Working on
, is n
h re
Fuel Supply System
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
♦ The fuel supply line is under pressure. Always wear pro‐
tective eyewear and protective clothing to prevent injuries
l purpos
and contact with skin. Place a cleaning cloth around the

connection point before loosening hose connections. Re‐
move the hose connection carefully to reduce the pres‐
nform
ercia
sure.
m
at
om
For safety reasons, switch off the current to the fuel pump be‐
ion
c
fore opening the fuel system. Otherwise the fuel pump will be
in t
or
his
e
activated when the driver door is opened. Use one of the fol‐
at
do
riv
lowing ways to switch off the current:

p
cum
for
♦ Disconnecting the battery
en
ng
t.
yi Co
op py
or t. C rig
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pyri by
♦ Removing the fuse for the Fuel Pump Control Module -
o Vo
by c lksw
cted
J538-
agen
Prote AG.
or
♦ Disconnecting the connector on the fuel delivery unit
flange or on the Fuel Pump Control Module - J538- .
Caution

space.
or hot components.
To Reduce the Risk of Personal Injury and/or Damage to the Fuel

Injection and Ignition System, Observe the Following:
♦ Do not touch or disconnect the ignition coils with power output
stages when engine is running or at starting speed.
♦ The ignition must be switched off before connecting or dis‐
connecting fuel injection and ignition system wiring or tester
cables.
Always Pay Attention to the following When Removing and In‐
stalling the Fuel Level Sensor or the Fuel Pump (Fuel Delivery
Unit) from Full or Partially Filled Fuel Tanks.
♦ Before starting work, place the extracting hose on an exhaust
extracting system that is switched on near the fuel tank instal‐
lation opening. This will extract the fuel vapors. If no exhaust
extraction system is available, a radial fan (as long as motor
272 Rep. Gr.20 - Fuel Supply

is not in air flow) with a delivery volume greater than 15 m3/h

can be used.
♦ Do not let fuel come in contact with skin. Wear fuel-resistant
gloves.
If Special Testing Equipment Is Required during a Road Test, Pay
Attention to the Following:
♦ Testing and measuring instruments must be secured on the
rear seat and operated by a second person from that location.
♦ If the vehicle is involved in a collision while testing and meas‐
uring equipment is operated from the front passenger seat, the
person sitting in that seat could be seriously injured when the
airbag deploys.
lkswage es n
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byV ua
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un
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Safety Precautions 273

2 Guidelines for Clean Working Condi‐

tions
When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules” for cleanliness: en AG. V
olkswagen AG
ag does
ksw not
♦ Thoroughly clean the connection points and the Vol
by surrounding gu
ara
area before loosening. ris
ed
nte
ho eo
ut
♦ Place the removed parts on a clean surface
ss
a and cover them. ra
c
Only use lint-free cloths.
ce
e
nl
pt
du
an
♦ Carefully cover or seal opened components if the repair is not
itte
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performed immediately.
erm
ab
ility
ot p
♦ Install only clean parts: remove the replacement parts from
wit
, is n
their packaging just before installing them. Do not use parts
h re
hole
that have been loosely stored or unpackaged (for example, in
spec
tool boxes etc.).
es, in part or in w
t to the co
♦ When the fuel system is open: avoid working with compressed
air if possible. Do not move the vehicle if possible.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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Prote AG.

3 Fuel Tank, Passat and CC

⇒ “1 Safety Precautions”, page 272 .
⇒ “3.2 Overview - Fuel Tank, Engine Codes”, page 276 .
⇒ “3.3 Fuel Tank, Draining”, page 277 .
⇒ “3.4 Fuel Tank, Removing and Installing”, page 281 .
3.1 Overview - Fuel Tank, Engine AGCodes

. VolkswageBZB,
n AG d CAWA, CAWB, CGYA, CCZA,
agen
CCZB, CDAA and CDAB
oes
olksw not
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ed ran
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th or
1 - Fuel Line au ac
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2 - Cap
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4 - Fuel Filler Door Unit
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Fuel Filler Door Unit;

Fuel Filler Door Unit,
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❑ Draining. Refer to
AG.
⇒ “3.3 Fuel Tank, Drain‐

ing”, page 277 .
ling. Refer to
⇒ “3.4 Fuel Tank, Re‐
page 281 .
8 - Mounting Strap
9 - Heat Shield
10 - Lock Washer
11 - 25 Nm
❑ Always replace
❑ Only use bolts with loose washers to secure the fuel tank mounting straps. If other bolts are used, the
mounting straps could twist when the bolts are tightened. Bolts. Refer to the Parts Catalog.
12 - Seal
❑ Always replace
❑ Insert dry into the fuel tank opening
❑ Coat with fuel only when installing the flange
3. Fuel Tank, Passat and CC 275

13 - Fuel Delivery Unit

❑ Removing and installing. Refer to ⇒ “7.1 Fuel Delivery Unit, Removing and Installing”, page 319 .
❑ Fuel Pump, Checking. Refer to ⇒ “7.3 Fuel Pump, Checking”, page 324 .
❑ Fuel Level Sensor - G- , Removing and installing. Refer to
⇒ “7.2 Fuel Level Sensor G , Removing and Installing”, page 322 .
14 - Suction Jet Pump
15 - Flange with Fuel Filter
❑ With pressure relief valve 6.2 bar (89.92 psi)
16 - Locking Ring, 110 Nm
❑ Remove and install with the Wrench - Fuel Sending Unit - T10202-
3.2 Overview - Fuel Tank, Engine Codes
1 - Fuel Line
2 - Cap
❑ Replace if damaged lkswage es n
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3 - Bolt ir se
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4 - Fuel Filler Door Units au ac
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ab
Exterior; Rep. Gr. 55 ;

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Fuel Filler Door Unit;

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Fuel Filler Door Unit,

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9 - Clamp
10 - Fuel Tank
❑ Draining. Refer to ⇒ “3.3 Fuel Tank, Draining”, page 277 .
❑ Removing and installing. Refer to ⇒ “3.4 Fuel Tank, Removing and Installing”, page 281 .
❑ Support while removing with the Engine and Gearbox Jack - VAS6931- .

11 - Mounting Straps
12 - Heat Shield
13 - Lock Washer
14 - Bolt
❑ 25 Nm
❑ Always replace
15 - Seal gen AG
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❑ Fuel Pump, Checking. Refer to ⇒ “7.3 Fuel Pump, Checking”, page 324 .
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17 - Pop Rivet
18 - Protective Plate
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❑ For the filler neck
19 - Suction Jet Pump
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20 - Flange with Fuel Filter f inform
❑ With pressure relief valve 6.2 bar (89.92 psi)

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21 - Locking Ring
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3.3 Fuel Tank, Draining
Prote AG.

⇒ “3.3.2 Fuel Tank, Draining with Fuel Pump Installed”,
page 278
⇒ “3.3.3 Fuel Tank, Draining When More than 3/4 Full”,
page 279
⇒ “3.3.4 Fuel Tank, Draining When Less Than 3/4 Full”,
page 280
3.3.1 General Information

♦ Fuel Extraction Unit - VAS5190-
♦ Wrench - Fuel Sending Unit - T10202-
– Read the safety precautions before starting. Refer to

Fuel Tank, Draining with Fuel Pump Installed. Refer to

page 278 .
Draining a Fuel Tank More than 3/4 Filled. Refer to
page 279 .
Draining a Fuel Tank When Less than 3/4 Full. Refer
. Volkto
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⇒ “3.3.4 Fuel Tank, Draining When Lessol swa 3/4 Full”,
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♦ Fuel Extraction - Adapter 3 - VAS5190/3-
ot
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♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565-
h re
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spec
♦ Injection Rate Comparison Meter Kit - Remote Cable -
es, in part or in w
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WARNING
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♦ Connect the Fuel Extractor - VAS5190- ground strap with thi

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Note
Press the locking ring to release the fuel lines.
– Connect the Fuel Extraction Unit - VAS5190- and Fuel Ex‐

traction - Adapter 3 - VAS5190/3- to the fuel supply line.
– Remove the bench seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats;Bench Seat, Removing and Installing .

– Remove the cover -1- and Fuel Pump Control Module - J538-
-2- from the fuel delivery unit.
– Disconnect the connector -A- from the fuel delivery unit flange.
– Attach the Vehicle Diagnostic Tester - Test Adapter - 5 Pin -

VAS5565- to the connector and to the fuel delivery unit.
– Connect the Injection Rate Comparison Meter Kit - Remote
Cable - VAG1348/3A- to the Vehicle Diagnostic Tester - Test
Adapter - 5 Pin - VAS5565- and the battery positive (+).
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This step allows the fuel pump to run when
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– Remove the cap from the fuel filler neck.

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– Operate the Injection Rate Comparison Meter Kit - Remote

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Cable - VAG1348/3A- and the shut-off valve on the Fuel Ex‐

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tractor - VAS5190- until the fuel tank is empty.

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Caution
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Do not run the fuel pump when it is »dry«.

rrectness of i
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3.3.3 Fuel Tank, Draining When More than 3/

4 Full
nform
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Caution
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Secure the Fuel Extraction Unit - VAS5190- ground wire to a

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♦ Shaft piece -1- is not used!
hole
spec
♦ A door is located in the fuel tank on the lower end of the filler
es, in part or in w
t to the co
neck. It must not be damaged by the extracting hose. There‐
fore slide in hose only up to the marking applied earlier.
rrectness of i
– Empty the fuel tank as much as possible via the filler neck.
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– Carefully pull out the suction hose.
nform
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Note
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♦ When no more fuel can be extracted, the fuel tank is only
r
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emptied enough so that the sensor flange can be opened
s
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safely. The tank may be removed while containing the remain‐ do

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♦ How to drain fuel tank completely. Refer to
Co
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⇒ “3.3.4 Fuel Tank, Draining When Less Than 3/4 Full”, page
t. C rig
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3.3.4 Fuel Tank, Draining When Less Than 3/

4 Full
WARNING

– Release the connector -1- and fuel line -2- from the flange
-3- and remove.
Note
♦ Press the locking ring to release the fuel line.

♦ If the vehicle has an auxiliary heater, then disconnect the con‐
nector and the fuel line from the Metering Pump - V54- .

– Open the locking ring using the Wrench - Fuel Sending Unit -
T10202- .
Caution
Do not bend the Wrench - Fuel Sending Unit - T10202- and

push hard on the locking ring. If the wrench slides down, the
fuel delivery unit can be damaged.
– Lift the sensor flange.

– Insert the Fuel Extraction Unit - VAS5190- suction hose as far
as possible into the fuel tank and extract the fuel.
If the fuel tank should only be drained, re-install the sensor flange.
Refer to
⇒ “7.1 Fuel Delivery Unit, Removing and Installing”, page 319 .
3.4 Fuel Tank, Removing and Installing

⇒ “3.4.2 Fuel Tank, Removing”, page 281 .
⇒ “3.4.3 Fuel Tank, Installing”, page 283 .

Fuel Tank, Removing. Refer to
⇒ “3.4.2 Fuel Tank, Removing”, page 281 .
Fuel Tank, Installing. Refer. Vto
olkswagen AG
⇒ “3.4.3 Fuel Tank,
ksw
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♦ Follow all the guidelines for clean working conditions. Refer to

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⇒ “2 Guidelines for Clean Working Conditions”, page 274 .

spec
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♦ Overview - Fuel Tank. Refer to

t to the co
⇒ “3.1 Overview - Fuel Tank, Engine Codes BZB, CAWA,

CAWB, CGYA, CCZA, CCZB, CDAA and CDAB”, page 275 .
rrectness of i
– If necessary, empty the fuel tank using the Fuel Extraction Unit
l purpos
- VAS5190- . Refer to ⇒ “3.3 Fuel Tank, Draining”, page 277 .

– Lower the rear subframe. Refer to ⇒ Suspension, Wheels,
nform
ercia
Steering; Rep. Gr. 42

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– Disconnect the 5-pin connector -arrow- from the flange.
o
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mer
Note
atio
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Disconnect the connector from the Metering Pump - V54- if the
thi
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a
vehicle has an auxiliary heater.

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en
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– Remove the right rear wheel.

t.
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Cop py
t. rig
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co lksw
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cted agen
Prote AG.
– Remove right rear wheel housing liner. Refer to ⇒ Body Ex‐

terior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Hous‐
ing Liner, Removing and Installing .
– Disconnect the vent lines and the vacuum line -arrows- from
the EVAP canister.
– Unclip the wire from the filler neck -arrows-.
– Remove the fuel filler door unit bolt and the fuel filler door unit.
Refer to ⇒ Body Exterior; Rep. Gr. 55 ; Fuel Filler Door Unit;
Fuel Filler Door Unit, Removing and Installing .

– Remove the fuel filler tube -arrows-.

AG. Volkswagen AG d
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The fuel supply line is under pressure.
ss a Always wear protective ra
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– Disconnect ventilation line (white) -1- and fuel line (black) -2-
from the connection point.
rrectne
Note
ss o
cial p
f
inform
mer
♦ If the vehicle has an auxiliary heater, disconnect the fuel line
atio
for the Metering Pump - V54- .
om
n
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n thi
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– Lower the rear axle. Refer to ⇒ Suspension, Wheels, Steering;

t
sd
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Rep. Gr. 42 ; Drive Axle

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Note
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♦ When lowering, ensure the brake lines and wires have suffi‐
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Prote
cient clearance.
AG.
♦ Have a second technician help when disconnecting and low‐

ering the fuel tank.
– Hold the fuel tank and remove the bolts for the mounting straps
-arrows-.
– Remove the mounting straps.
– Lower the fuel tank slowly with a second technician and guide
it out between the rear axle and the vehicle body.
3.4.3 Fuel Tank, Installing

– With a second technician assisting, guide the fuel filler neck
between the rear axle and body.

– Hold the fuel tank in its installed position and install the new
bolts -arrows-.
Note
Only use bolts with loose washers to secure the fuel tank mount‐
ing straps. If other bolts are used, the mounting straps could twist
when the bolts are tightened. Bolts. Refer to the Parts Catalog.
– Secure rear axle to body again. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 42 ; Drive Axle .
Installation is performed in reverse order of the removal. Note the
following:
♦ Make sure the vent and fuel lines are routed without kinks.
♦ Make sure the line connections are secure.
♦ Check the fuel tank/body ground connection on the filler neck.
– Fill at least five liters (5.28 quarts) of fuel in the fuel tank.
WARNING
There is a risk of the fuel tank exploding! After installing a new

or completely emptied fuel tank, fill it immediately with a mini‐
mum of five liters (5.28 quarts) of fuel. Do not allow the fuel
pump to run when the fuel tank is completely empty.
Tightening Specifications:
Component Tightening Specification
Mounting straps to vehicle body 25 Nm
♦ Use new bolts. agen
AG. Volkswagen AG d
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♦ Only use bolts with loose ed byV gu
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washers to secure the fuel tank horis nte
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mounting straps. This prevents s aut ra
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the mounting straps from twist‐ s
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ing when tightening the bolts.

un
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Filler tube to body 8 Nm +90°

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Subframe/rear axle to the vehicle Refer to ⇒ Suspension,

wit
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body Wheels, Steering; Rep. Gr.

h re
ole,
♦ Use new bolts. 42 ; Drive Axle .

spec
t to the co
Wheel, Mounting Refer to ⇒ Suspension,

Wheels and Steering; Rep.
Gr. 44 ; Tightening Specifi‐
cation for Mounting Wheels .
rrectness o
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f inform
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Cop py
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4 Fuel Tank, Rabbit

⇒ “4.2 Overview - Fuel Tank, Engine Codes”, page 287 .
⇒ “4.4 Fuel Tank, Draining, Engine Codes”, page 293 .
4.1 Overview - Fuel Tank, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA,
CCZB and CDAA
1 - Bolt
2 - Cap
4 - 10 Nm
5 - Wiring Guide
6 - 25 Nm
❑ Always replace
❑ Only use bolts with AG. Volkswagen AG d
agen
loose washers Vol to
ksw secure oes
not
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the fueledtankby mounting ara
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straps.
thoris
If other bolts are eo
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s au the mounting ra
c
straps could twist when
s
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le
the bolts are tightened.

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Bolts. Refer to the Parts

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7 - Fuel Tank
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❑ Support while removing

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spec
with the Engine and

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Gearbox Jack -
t to the co
VAS6931- .
ling. Refer to
rrectness of i

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page 294 .
nform
ercia
8 - Lock Washer
m
9 - Exhaust System Bracket

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tion in
10 - Mounting Strap
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11 - Heat Shield
n
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Cop py
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12 - Supply Line
rig
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❑ To the fuel rail
co lksw
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AG.
13 - Fuel Filter
❑ Installation position. Refer to ⇒ Fig. ““Fuel filter installation position”“ , page 287
❑ The arrow points in the flow direction
14 - Vent Line
❑ Attached to the side of the fuel tank
4. Fuel Tank, Rabbit 285

15 - Seal
❑ Always replace
❑ Fuel Pump, Checking. Refer to ⇒ “8.3 Transfer Fuel Pump G6 , Checking”, page 342 .
❑ Pay attention to the fuel tank installation position. Refer to
⇒ Fig. ““Fuel delivery unit flange installation position”“ , page 286
❑ With the Fuel Level Sensor - G-
17 - Locking Ring, 110 Nm
18 - Supply Line
❑ Black
❑ Make sure it is secure wage es n
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19 - Return Line ris
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❑ Blue au
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❑ Removing and installing. Refer to ⇒ Body Exterior; Rep. Gr. 55 ; Fuel Filler Door Unit; Fuel Filler Door
hole
spec
Unit, Removing and Installing .

es, in part or in w
t to the co
Fuel delivery unit flange installation position

rrectness of i
• The tab -2- on locking flange must lie between tabs -1- and
l purpos
-3- on the fuel tank.

• The -arrow- points in the direction of travel.
nform
mercia
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tion in
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Fuel filter installation position AG. Volkswagen AG d

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The pin -2- on filter housing must d by V engage in recess of the guidet gua
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4.2 Overview - Fuel Tank, Engine Codes
rrectne
1 - Bolt
ss
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form
mer
3 - Vacuum Line
atio
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❑ To the Leak Detection
c
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Pump - V144-
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4 - Bolt
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5 - Rivet
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❑ Riveted to lower clamp
at factory
❑ When replacing fuel
tank, lay protective plate
on filler tube and rivet
clamp
7 - Wiring Bracket
❑ Clipped to the shield
8 - Bolt
❑ 25 Nm
❑ Always replace
❑ Only use bolts with
loose washers to secure
the fuel tank mounting
straps. If other bolts are
used, the mounting
Bolts. Refer to the Parts
Catalog.
9 - Fuel Tank
with the Engine and Gearbox Jack - VAS6931- .
10 - Lock Washer
12 - Mounting Strap
❑ Note the installation position

13 - Heat Shield
14 - Supply Line
15 - Fuel Filter
❑ Installation position. Refer to ⇒ Fig. ““Fuel Filter Installation Position”“ , page 289
16 - Vacuum Line
❑ From the Leak Detection Pump - V144- to the intake manifold
17 - Vent Line
❑ From EVAP canister to the EVAP Canister Purge Regulator Valve 1 - N80-
18 - Seal
❑ Always replace
❑ If fuel delivery unit was replaced, adapt the engine control AGmodule
. Volkswato
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AG dfuel pump. Refer to Vehicle
Diagnostic Tester in “Guided Functions”. agen oes
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❑ Fuel Pump, Checking. Refer to ⇒ “8.3 Transfer rise
d b Fuel Pump G6 , Checking”, page 342
ara
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❑ Pay attention to the fuel tank installationau position. Refer to
th
ra
⇒ Fig. ““Fuel Delivery Unit Flange Installation
ss Position”“ , page 289 c
ce
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un
❑ With the Fuel Level Sensor - G- pt

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❑ Fuel Level Sensor - G- , Removing and installing. Refer to y li

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⇒ “8.2 Fuel Level Sensor G , Removing and Installing”, page 341 . ility
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20 - Locking Ring
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❑ 110 Nm
t to the co

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21 - Return Line
❑ Blue
ss o

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atio
22 - Cap
om
n
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❑ Removing and installing. Refer to ⇒ Body Exterior; Rep. Gr. 55 ; Fuel Filler Door Unit; Fuel Filler Door Cop py
Unit, Removing and Installing . ht. rig
rig ht
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24 - To the EVAP Canister
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Prote AG.
25 - Supply Line
❑ Black

Fuel Delivery Unit Flange Installation Position

• The tab -2- on locking flange must lie between tabs -1 and 3-
on the fuel tank.
Fuel Filter Installation Position

The pin -2- on filter housing must engage in recess of the guide
-1- on filter bracket.
AG. Volkswagen AG d
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distance -a- = 1,180 mm from end of suction hose.
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292 .

4 Full

WARNING

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Refer to
4.4 Fuel Tank, Draining, Engine Codes



Caution

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♦ A pressure point can be sensed after approximately 120 cm.

The check valve in the fuel tank must be pushed open. Pull
out hose slightly and slide it in using a light jerk.
♦ Fuel tank is drained almost completely.
♦ Remove the hose the same way.

Removing the Fuel Tank:
– Follow all the guidelines for clean working conditions. Refer to
- VAS5190- .

Refer to
⇒ “4.4 Fuel Tank, Draining, Engine Codes”, page 293 .
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or
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Fuel Filler Door Unit; Fuel Filler Door Unit, Removing and In‐
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– Remove the heat shield from the center and rear mufflers.
WARNING

Note

– Disconnect the vent line -1- (white) and fuel line -2- (black) at
the connecting point.
Note
♦ On USA/Canada vehicles, the Leak Detection Pump - V144-

vacuum line must also be disconnected.
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5 Fuel Tank, Tiguan

⇒ “5.1 Overview - Fuel Tank”, page 297 .
5.1 Overview - Fuel Tank
1 - Cap
2 - Bolt
4 - Vent Line
❑ To the EVAP Canister
5 - Locking Ring
❑ 110 Nm
❑ Remove and install us‐
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⇒ Fig. ““Installation Lo‐ rrectne
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Level Sensor 2 -
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❑ With suction jet pump
❑ With a pressure relief valve
5. Fuel Tank, Tiguan 297

❑ With fuel filter
⇒ “9.4 Fuel Level Sensor 2 G169 , Removing and Installing”, page 365 .
9 - Nut
❑ 3.5 Nm
10 - Fuel Pump Control Module - J538- Bracket
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14 - Bolt
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20 - Vent Line
21 - Bolt
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Installation Location of the Fuel Delivery Unit Flange and Fuel

Level Sensor 2 - G169- .
Fuel delivery unit -3-:
The tab -1- points in direction of travel.
Fuel Level Sensor 2 - G169- -2-:
The tab -1- points in direction of travel.
Note
Ignore the arrows on the locking rings.

page 299 .
page 301 . n AG. Volkswagen A ge G do
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⇒ “5.2.4 Fuel Tank,
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VAG1348/3A-

WARNING

sure.
♦ Connect the Fuel Extraction Unit - VAS5190- ground strap

Note
– Connect the Fuel Extraction Unit - VAS5190- and Fuel Ex‐ . Volkswag
traction - Adapter 3 - VAS5190/3- to the fuel supply kline.
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– Using insulating tape, apply a mark on the hose -arrow-
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neck. It must not be damaged by the extracting hose. There‐
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302 .

4 Full
– Remove the cover from the fuel delivery unit.
WARNING

– Disconnect the connector and remove the fuel lines from the
flange.
Note
Press buttons together on hose connections to do so.


3087- .
– Raise the fuel delivery unit.
If the fuel tank only needed to be emptied, install the fuel delivery
unit again. Refer to

Removing
– See if a coded radio is installed. If so, obtain the anti-theft code.
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39 .
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WARNING
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Fuel supply lines are under pressure! Wear protective eyewear
m
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well.
Note

– Disconnect the vent lines and the vacuum line -arrows- from
the EVAP canister.

– Unclip the wheel sensor wire -arrows- from the retainer on the
filler neck.
– Remove the fuel filler door and the fuel filler cap.
– Disconnect the ground cable from the fuel filler tube.

– Remove the mounting strap and bolts -arrows-. Support the

fuel tank using the Engine and Gearbox Jack - VAS6931-
when doing this.
Installing
– With a second technician assisting, guide the fuel filler neck
between the rear axle and body. Then place
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when the bolts are tightened.
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– Tighten the new bolts on the tension straps -arrows- and the
new bolt -1- to 25 Nm.
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– Tighten the bolts -arrows- for the fuel filler tubehorto
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6 Fuel Tank, Eos

⇒ “6.2 Overview - Fuel Tank, Engine Codes CBFA, CCTA”, page
309 .
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6.1 Overview - Fuel Tank, Engine Codes CAWA, CAWB, CCZA and CCZB
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6 - 25 Nm
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ling. Refer to
page 315 .
8 - Lock Washer
10 - Mounting Strap
sition
loose washers to secure the fuel tank mounting straps. If other bolts are used, the mounting straps could
twist when the bolts are tightened.
11 - Heat Shield
12 - Supply Line
13 - Fuel Filter
❑ Installation position. Refer to ⇒ Fig. ““Fuel filter installation position”“ , page 309
14 - Vent Line
6. Fuel Tank, Eos 307

15 - Seal
❑ Always replace
❑ Fuel Pump, Checking. Refer to ⇒ “8.3 Transfer Fuel Pump G6 , Checking”, page 342 .
❑ Pay attention to the fuel tank installation position. Refer to
⇒ Fig. ““Fuel delivery unit flange installation position”“ , page 308
❑ With the Fuel Level Sensor - G-
17 - Locking Ring
❑ 110 Nm
18 - Supply Line
❑ Black
19 - Return Line
❑ Blue
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Fuel filter installation position

6.2 Overview - Fuel Tank, Engine Codes CBFA, CCTA
1 - Bolt
3 - Bolt
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⇒ “6.4.1 Removing”, page 315 .
9 - Lock Washer
11 - Mounting Strap
❑ Note the installation position

12 - Heat Shield
13 - Supply Line
14 - Fuel Filter
❑ Installation position. Refer to ⇒ Fig. ““Fuel Filter Installation Position”“ , page 311
15 - Vacuum Line
❑ Green
❑ From the Leak Detection Pump - V144- to the intake manifold
16 - Vent Line
❑ White
❑ From EVAP canister to the EVAP Canister Purge Regulator Valve 1 - N80-
17 - Seal
❑ Always replace
❑ Coat the inside with fuel only when installing the flange
❑ Fuel Pump, checking. Referwatoge⇒ n A“8.3
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kswagen AGFuel Pump G6 , Checking”, page 342 .
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⇒ Fig. ““Fuel Delivery
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⇒ “6.3.1 General Information”, page 311 Prote
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page 312
page 313
page 314



page 312 .
Draining a Fuel Tank More Than 3/4 Filled. Refer to
page 313 .
Draining a Fuel Tank When Less than 3/4 Full. Refer to
page 314 .

stalled
VAG1348/3A-
WARNING

and contact with skin. Place a cleaning cloth around the agen
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Caution

4 Full
Caution


– Remove the cone piece -2- from the shaft piece -1- on the Fuel
Extraction Unit - VAS5190- .
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en AG. does
distance -a- = 820 mm from the end of the suctionbyhose.
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es, in part or in w
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earlier -arrow- meets the filler neck.
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Note
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There is a ball joint in the fuel tank on the lower end of the filler
tube that must not be damaged by the suction hose -1-. Therefore
slide in hose only up to the marking -arrow- applied earlier.
nform
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– Drain the fuel tank as much as possible.
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♦ If it is necessary to drain the fuel tank completely, proceed as

follows. Refer to
314 .

4 Full
WARNING


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AG
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e an
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– Disconnectsthe
au connector
t
-arrow-. or
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– Remove the fuel lines -1 and 2- from the flange.
nform
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T10202- and raise the flange slightly.
Caution


Refer to

⇒ “6.4.1 Removing”, page 315
⇒ “6.4.2 Fuel Tank, Installing”, page 317
6.4.1 Removing

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– Disconnect the connector -arrow-. byV
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– Remove the bolts from the fuel filler door unit and then remove
h re
the fuel filler door unit. Refer to ⇒ Body Exterior; Rep. Gr. 55 ;
hole
spec
Fuel Filler Door Unit; Fuel Filler Door Unit, Removing and In‐
es, in part or in w
stalling .
t to the co
– Remove tension struts -A and B-. Refer to ⇒ Suspension,
rrectness of i
Wheels, Steering; Rep. Gr. 42 .
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– Press the securing ring in and disconnect the breather line
-1- (white) behind the fuel tank.

– Press the circlip in and disconnect the vacuum line -2- (green)
for the Leak Detection Pump - V144- behind the fuel tank.
WARNING
The fuel system is under pressure! Always wear protective

– Disconnect the vent line -1- (white) and fuel line -2- (black) at
the connecting point.
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– Remove the mounting strap and bolts -arrows-. Support the

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fuel tank using the Engine and Gearbox Jack - VAS6931-

t to the co
when doing this.
– Carefully lower the fuel tank.

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6.4.2 Fuel Tank, Installing
cop Vo
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♦ Only use bolts with loose washers to secure the fuel tank
mounting straps. If other bolts are used, the mounting straps
could twist when the bolts are tightened.
♦ Do not confuse the supply line and the return line (the return
line is blue and the supply line is black).

WARNING

– Install the tension struts. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 42 .
Tightening Specifications: agen
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Fuel tank to chassis - M6 boltsauth
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7 Fuel Supply, Servicing, Passat and

CC
⇒ “7.2 Fuel Level Sensor G , Removing and Installing”,
page 322 .
⇒ “7.3 Fuel Pump, Checking”, page 324 .
7.1 Fuel Delivery Unit, Removing and In‐

stalling
Note
♦ Fuel hoses at engine may only be secured with spring-type

clamps appropriate for the model type.
♦ Spring Clip Pliers - VAS6499- or the Hose Clip Pliers -
VAS6362- is recommended for installing spring clamps.
Safety Precautions when Working on Fuel Supply System. Refer

to ⇒ “1 Safety Precautions”, page 272 .
Guidelines for clean working conditions. Refer to
Remove the Fuel Delivery Unit:
Caution
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♦ When replacing the fuel delivery unit, check the fuel tank for
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visible contamination and clean if necessary.

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7. Fuel Supply, Servicing, Passat and CC
4-Cylinder Fuel Injection Engine (1.8L and 2.0L Engine, Chain Drive). V- oEdition
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– Remove the cover -1- and Fuel Pump Control Module - J538- db
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– First pull on the connector -A- without pressing the locking
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mechanism to make sure it connected securely. If the con‐
nector was not connected correctly, it could cause a malfunc‐
s
tion.
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– Disconnect the connector.
form
mer
– Check the contacts on the connector and the fuel delivery unit
atio
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for damage.
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nection carefully to reduce the pressure. Prote AG.
– Remove the fuel line -B- from the flange.
Note

T10202- .
Caution

– Lift the flange.
Note
Press in the circlip to disengage coupling -A-.

– Disconnect the coupling -A- and remove suction jet pump

-B-. To do so, press tabs in direction of -arrows- together.
– Pull the sealing ring and the fuel delivery unit out of fuel tank
opening.
Note
♦ If the delivery unit is to be replaced then drain old delivery unit

before disposal.
♦ Follow the disposal regulations.
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Install the Fuel Delivery Unit: d byV
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-A-. Pull on the coupling to make sure it is fastened securely.
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Make sure the hoses are correctly fastened.
7. Fuel Supply, Servicing, Passat and CC 321

– Now pull the sealing ring -A- over flange and insert it into fuel
tank opening.
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– Coat the sealing ring lightly with fuel and press the flange into olkswag does
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– Pay attention to the installed position: the marking -A- points es, in part or in w
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in opposite direction of travel.
– Tighten the locking ring using the Wrench - Fuel Sending Unit
rrectness of i
- T10202- . Tightening specification -item 16-
⇒ Item 16 (page 276) .
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Installation is performed in reverse order of the removal. Note the

following:
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7.2 Fuel Level Sensor - G- , Removing and

Installing
Note

Fuel Level Sensor , Removing:

– Install the fuel delivery unit. Refer to
⇒ “7.1 Fuel Delivery Unit, Removing and Installing”,
page 319 .

– Pull the Fuel Level Sensor - G- slightly to the side and upward
at the same time.
– If the sensor cannot be released this way, also press the re‐
taining tab -arrows- to the side slightly.
– Note the wire color coding for installing later.
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– Release and disconnect the connectors -1 throughth3-.
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livery unit and push down until it engages.
t to the co
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– Install the fuel delivery unit. Refer to ⇒ page 321 .
ss o
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⇒ “7.3.1 General Information”, page 324 au ac
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⇒ “7.3.2 Function and Power Supply, Checking”, page 324
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⇒ “7.3.3 Fuel Pressure, Checking”, page 327
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⇒ “7.3.5 Residual Pressure, Checking”, page 330
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⇒ “7.3.6 Fuel Delivery Rate, Checking, Engine Codes”,
h re
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page 331
spec
⇒ “7.3.8 Current Draw, Checking”, page 336 es, in part or in w
t to the co
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Note
When replacing the fuel delivery unit, check the fuel tank for visi‐
nf
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ble contamination and clean if necessary.
rm
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♦ Pressure Tester Kit - VAS6550-

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♦ Analog/Digital Multimeter - FLU83III- Prote
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♦ Measuring container, minimum 3 liters (3.17 quarts)
7.3.2 Function and Power Supply, Checking

• Battery voltage minimum 11.5 V.
• Fuel pump fuse on the fuse panel OK. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
• Fuel Pump Control Module - J538- OK
Note
♦ The output diagnostic test mode checks the fuel pump func‐
tion.
♦ If the output diagnostic test mode is performed several times
in succession, it may be necessary to briefly start the motor
before repeating the output diagnostic test mode.

– Connect the Vehicle Diagnostic Tester as follows:

– Connect the diagnostic cable connector to the diagnostic con‐
nection inside the driver footwell.
– Switch the ignition on.
– Press the buttons for Vehicle Self-Diagnosis , Engine
Electronics and Output Diagnostic Test Mode (DTM)
one after another on the display.
– Press the right arrow button ► on the display until output di‐
agnostic test mode for the fuel pump electronics is reached.
The fuel pump must now accelerate slowly up to the maximum
RPM.
Note
The fuel pump runs very quietly.
– Switch off the ignition.

If the Fuel Pump Does Not Start:
– Disconnect connector from Fuel Pump Control Module -

J538- . n AG. Volkswagen AG
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– Check the voltage supply between terminals -1 and 6- using

t to the co
an Analog/Digital Multimeter - FLU83III- .

• Specified value: approximately battery voltage
rrectne
Voltage Supply Not OK:

ss
– Locate and repair the open circuit according to the wiring dia‐
o
cial p
gram. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐

inform
ponent locations.
mer
atio
m
Voltage Supply OK:

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nector was not connected correctly, check the fuel pump
function again.
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The fuel supply line is under ut pressure. Always wear protective
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nection carefully to reduce the pressure. y li

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– Remove the fuel line -B- from the flange.

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T10202- .
Caution

– See if the wires between the flange and the fuel pump are
connected.
If No Open Circuits Are Found:
– Replace the fuel delivery unit if the fuel pump is faulty. Refer
to
page 319 .
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7.3.3 Fuel Pressure, Checking
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Test Conditions: hor eo
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• Check the functionality of the fuel pump. Refer to ss
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⇒ “7.3.2 Function and Power Supply, Checking”, page 324 .

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Test Sequence
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Note
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♦ The fuel pressure must be checked using output diagnostic
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test mode. If the fuel pressure is measured in idle, it can differ
from the specified value.
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Read the safety precautions before starting. Refer to

nform
⇒ “1.1 Safety Precautions when Working on Fuel Supply System”,

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page 272 .
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– Follow all the guidelines for clean working conditions. Refer to

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– Connect the Pressure Tester Kit - VAS6550- to the fuel supply
t to the co
line using the Pressure Tester Kit - Hose 1 - VAS6550/1- and
Pressure Tester Kit - Hose 2 -VAS6550/2- .
rrectness of i
– Make sure the drain is closed and the shut-off valves are open.
l purpos
– Activate the fuel pump using the output diagnostic test mode
to build the fuel pressure.
nform
ercia
– Check the fuel pressure on the pressure gauge.

m
a
• Target value: 4.0 to 7.0 bar (58 to 101.5 psi)
com
tion in
r
If the fuel pressure is OK, check the residual pressure. Refer to

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⇒ “7.3.5 Residual Pressure, Checking”, page 330 .
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If the Specified Value Is Exceeded:
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– Pressure relief valve in flange is faulty, replace flange with fuel Cop py
filter -item 15- ⇒ Item 15 (page 276) .
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If the Specified Value Is Not Obtained:
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– Check the fuel lines for possible restrictions (kinks) or block‐
ages.
– Replace the flange with fuel filter and the pressure relief valve
-item 15- ⇒ Item 15 (page 276) .
– Repeat the test.
If the specified value is not reached again:
to
page 319 .

7.3.4 Fuel Pressure, Checking while Driving,

Engine Codes CCZA, CCZB, CDAA and
CDAB
Note
♦ If there are concerns about the driving behavior, the cause

may be low fuel pressure. Malfunctions in the high pressure
area can also be caused by low pressure. This test checks the
high and low fuel pressure during a road test. The high fuel
pressure is read from the engine control module. The low fuel
pressure is measured through the Pressure Tester AG.Kit
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♦ Pressure Tester Kit - Hose 1 - VAS6550/1- and Pressure Test‐
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♦ Vehicle Diagnostic Tester
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♦ Vehicle Diagnosis System - Connection Lead - VAS5051/66-
rrectness of i
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– Remove the cover -1- with the Fuel Pump Control Module -
J538- -2- from the fuel delivery unit.
nform
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– Remove the supply line -arrow-
ss and
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wipe up the draining fuel ac
with a cleaning cloth.
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Press the locking ring to release the fuel line.
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nform
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Pressure Tester Kit - Hose 1 - VAS6550/1- .

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– Connect the Vehicle Diagnosis System - Connection Lead -
om
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VAS5051/66- to the Pressure Tester Kit - VAS6550- and to the
n
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Vehicle Diagnostic Tester .

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– Switch on the Pressure Tester Kit - VAS6550- .

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low the instructions from the vehicle diagnostic tester. p by
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If the fuel pressure test is done without “Guided Fault Finding”, Prote AG.
proceed as follows:
– Connect the Vehicle Diagnostic Tester to the vehicle.
– Select Guided Fault Finding in the Vehicle Diagnostic
Tester.
– Perform the vehicle identification.
– Use the GO TO button to select the following menu items:
♦ Function/component selection
♦ Motor
♦ Engine
♦ 24-fuel injection system
♦ Mechanical components
♦ High pressure pump
– Follow the instructions on the Vehicle Diagnostic Tester .
WARNING
Testing and measuring instruments must be secured on the

7.3.5 Residual Pressure, Checking
Note
If the output diagnostic test mode is performed several times in

succession, it may be necessary to briefly start the motor before
repeating the output diagnostic test mode.

Test Conditions
• Fuel pressure is OK and Pressure Tester Kit - VAS6550- con‐
nected. Check the fuel pressure. Refer to
⇒ “7.3.3 Fuel Pressure, Checking”, page 327 .
Test Sequence:
– End the OBD and turn off the ignition.
– Watch the pressure decrease on the pressure gauge. After 10
minutes the pressure must not drop below a 3.0 bar (43.5 psi).
If the pressure drops further:
– Close the shut-off valve -B- on the pressure gauge as soon as

pressure accumulates. The lever is perpendicular to the flow
direction.
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If the Pressure Drops Again (Leak onVFuel
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– Check fuel line to flangess-item
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15- ⇒ Item 15 (page 276) for c
leaks.
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– Replace the flange with the fuel filter -item 15- spec
⇒ Item 15 (page 276) and repeat the pressure retention test.
If the leak is still present, replace the fuel delivery unit.

t to the co
If the Pressure Stops Decreasing (Leak on the Engine Side):

rrectne
Note
ss o
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Check for the leak on the engine side. Repeat the residual pres‐
inform
sure check. Close the shut-off valve -A- this time to determine if
mer
there actually is a leak on the engine side.

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– If there is a leak on the engine side, check the fuel pipe and
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high pressure pump for leaks.

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If no malfunction is found, check the fuel injectors for leaks:

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– Remove the spark plugs. Open the shut-off valves -A and B-. . Cop py
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7.3.6 Fuel Delivery Rate, Checking, Engine

Codes
Test Conditions:
• Fuel level inside the fuel tank is above reserve

Test Sequence:

tion.
for damage.
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– Connect the Pressure Tester Kit - VAS6550- with the Pressure
ce
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Tester Kit - Hose 2 - VAS6550/2- to the fuel supply line. Hold
an
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the Pressure Tester Kit - Hose 1 - VAS6550/1- into a meas‐
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Danger of spraying when opening shut-off valve; wear protec‐
tive goggles and protective clothing to prevent injuries and
rrectness of i
contact with skin. Hold a container in front of the open con‐
nection of the pressure gauge.
l purpos
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Cable - VAG1348/3A- . Slowly close the shut-off valve
m
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-arrow- until the pressure gauge shows 4 bar (58 psi). From
com
tion in
this point on do not move the position of the shut-off valve.
r
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– Empty the measuring container.

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– The fuel pump delivery rate is dependent on the battery volt‐

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age. Due to this, also connect the Analog/Digital Multimeter - Cop py
FLU83III- to wires -1 and 5- from the Vehicle Diagnostic Tester
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- Test Adapter - 5 Pin - VAS5565- . op Vo
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– Operate the remote control for 60 seconds and simultaneously
AG.
measure the voltage on the fuel pump.

– Compare the quantity of fuel delivered with the specification.

*) Minimum delivery rate cm³/60 s
**) Voltage on the fuel pump with engine running in idle and the
pump is on.
Example:
During test, a voltage of 10.5 Volts is measured. This results in a
minimum delivery quantity of approximately 1200 cm³/60 s.
– Check the fuel line for possible restrictions (kinks) or clogging.
– Remove the cap from the fuel filler tube and repeat the test. If
the fuel delivery rate is now reached, check the fuelwtank
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If the Specified Value Is Not Reached Again:
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– Remove the fuel delivery unit and check
ss the fuel screen for
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debris.
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– If there is no malfunction here as well, replace the flange with
y li
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ab
the fuel filter.
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spec
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to
page 319 .
rrectness of i
Delivery rate has been obtained, but malfunctions are still sus‐
l purpos
pected in the fuel supply (for example, intermittent loss of fuel

supply):
nf
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– Check the fuel pump current draw. Refer to
rm
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⇒ “7.3.8 Current Draw, Checking”, page 336 . atio

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Codes CCZA, CCZB, CDAA and CDAB

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with the “Check fuel delivery rate, quick test” Guided Function.
Perform a second measurement on the fuel delivery unit flange if
the minimum delivery rate is not attained.
Checking the fuel delivery rate in the engine compartment:

– Select Guided Functions in the Vehicle Diagnostic Tester.
– Select engine .
– Select check fuel delivery rate, quick test .

Checking the fuel delivery rate on the flange:

Test conditions:
• “Check fuel delivery rate, quick test” was performed. Refer to
• The Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A- and wage
the
n AGVehicle
. VolkswagDiagnostic
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doe Tester - Test Adapt‐
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• Fuel
ss level inside the fuel tank is above reserve
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Test sequence:
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WARNING
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es, in part or in w
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– Remove the fuel line -arrow- and wipe up the leaking fuel with
nf
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a cleaning cloth.
rm
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Note
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– Connect the Pressure Tester Kit - VAS6550- using the Pres‐

sure Tester Kit - Hose 2 - VAS6550/2- to the flange. Hold the
Pressure Tester Kit - Hose 1 - VAS6550/1- into a measuring
container.
– Press the Injection Rate Comparison Meter Kit - Remote Ca‐
ble - VAG1348/3A- and slowly close the shut-off valve
-arrow- until 4 bar (58 psi) displays on the pressure gauge.
From this point on do not move the position of the shut-off
valve.


age. Due to this, also connect the Analog/Digital Multimeter -
FLU83III- to wires -1- and -5- from the Vehicle Diagnostic
Tester - Test Adapter - 5 Pin - VAS5565- .

pump is on.
Example:
If the specified value is not obtained:
the fuel delivery rate is now reached, check the fuel tank
breather.
– Remove the fuel delivery unit and check the fuel screen for
debris.
the fuel filter.
– Repeat the test. AG. Volkswagen AG d
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If the specified value is not reached again: by Vol not
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– Replace the fuel delivery unit if the fuel pump is tfaulty.
ho
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⇒ “7.1 Fuel Delivery Unit, Removing and Installing”, s
ce
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page 319 .
un
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supply): check the fuel pressure while driving. Refer to

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⇒ “7.3.4 Fuel Pressure, Checking while Driving, Engine Codes

h re
hole
CCZA, CCZB, CDAA and CDAB”, page 329 .

spec
es, in part or in w
t to the co
7.3.8 Current Draw, Checking

rrectness of i

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mercia
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tion in
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336
Prote AG.
Rep. Gr.20 - Fuel Supply

tion.
for damage.

VAS5565- to the connector
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– Connect theedcurrent
by probe -A- to the red wire with
gu
arthe
an word
“current tprobe”
h oris on the Vehicle Diagnostic Tester - Test teeAdapt‐
er - 5 sPin
au - VAS5565- .
or
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s
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– Start the engine and run at idle speed.

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– Measure the current draw of the fuel pump.

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• Specified value: maximum 10 amps

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Note
es, in part or in w
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♦ The fuel pump starting current may be higher than the speci‐
fied value briefly when starting the engine.
rrectness of i
♦ If the malfunction in the fuel system only occurs sporadically,

the test can also be performed during a road test. A second
l purpos
person is required to do this.

nform
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If the current draw is exceeded:

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page 319 .
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8 Fuel Supply System, Servicing, Golf

and Eos Volkswage es n
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⇒ “8.1 Fuel DeliveryorUnit,
ise Removing and Installing”, page 338an.tee
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⇒ “8.2 Fuel Level
ss Sensor G , Removing and Installing”,
a ac
page 341 .
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⇒ “8.3 Transfer Fuel Pump G6 , Checking”, page 342 .

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Note
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clamps appropriate for the model type.
♦ Hose Clip Pliers - VAS6340- and the Hose Clip Pliers -
ss
VAS6362- are recommended for installing spring-type clips.
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mer
atio
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Removing:
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Conditions: cted agen
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• The fuel tank may be a maximum of 3/4 full. This ensures

the fuel level is below the fuel delivery unit flange.
Note
♦ If necessary, empty the fuel tank using the Fuel Extraction Unit
- VAS5190- .
CAWB, CGYA, CCZA, CCZB and CDAA”, page 285 .


– Pull on the connector -arrow- without pressing the locking

mechanism to make sure it is connected securely. If the con‐
tion.
– Check the contacts on the connectoragand
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– Remove the fuel lines -1 and 2- from the flange. t to the co

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8. Fuel Supply System, Servicing, Golf and Eos 339

AG. Volkswagen
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf ksw2009 ➤ , Passat 2006e➤
agen AG do
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Vol
4-Cylinder Fuel Injection Engine (1.8L and
d b 2.0L Engine, Chain Drive) - Edition
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– Open locking ring using the Wrench - sFuel
au Sending Unit - ra
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T10202- and raise the flange slightly. s
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Caution
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– Pull the delivery unit and gasket out of the fuel tank opening.
rrectness of i
Note
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♦ If the delivery unit is to be replaced then drain old delivery unit
nform
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before disposal.
m
at
♦ Follow the disposal regulations.
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Installing:
at
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– Replace the seal.
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– Insert the dry fuel delivery unit gasket into the opening in the
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– Coat the inside of the gasket with fuel.
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– Be careful not to bend the fuel level sensor when installing the
fuel delivery unit.
– Press the sealing flange downward against the spring force

and bring it into the installation position.
• The tab -2- on locking flange must lie between tabs -1 and 3-
on the fuel tank.
– Tighten the sealing flange.
• Tightening specifications: 110 Nm
– Connect the supply line -1- (black).

– Connect the return line -2- (blue or has blue markings).

– Connect the connector -arrow-.

– Pull on the connectors and connector couplings to check if
they are securely fastened.
The rest of the assembly is performed in reverse order
8.2 Fuel Level Sensor - G- , Removing and

Installing
Removing:
page 338 .
– Pull the Fuel Level Sensor - G- slightly to the side and upward
at the same time.
AG. Volkswagen AG d
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– If the sensor cannot
byV
ol be released this way, also not press the re‐
gu
taining tabris-arrows-
ed to the side slightly. ara
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– Note sthe wire color coding for installing later.
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– Release and disconnect the connectors -1 through 3-. Bend

rrectne
the hooks back.

Installing:
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– Connect the connectors -1 through 3-. Pay attention to the

color coding.
– Pull on the connectors to make sure they are secure.
– Insert the Fuel Level Sensor - G- in the guide on the fuel de‐
livery unit and push down until it engages.
page 338 .
8.3 Transfer Fuel Pump - G6- , Checking

⇒ “8.3.1 General Information and Special Tools”, page 342
⇒ “8.3.6 Fuel Delivery Rate, Checking, Engine Codes”,
page 351
⇒ “8.3.8 Current Draw, Checking”, page 357
⇒ “8.3.9 Low Side Fuel Pressures”, page 358
8.3.1 General Information and Special Tools

n AG. Volkswagen A ge G do
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Special tools and workshop equipment
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♦ Injection Rate Comparison
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Hose 2 - VAS6550/2- between the fuel filter and fuel supply
line.

– Turn on the ignition and activate the fuel pump using the output
diagnostic test mode.
– Close the shut-off valve -A- while the fuel pump is running.
Pressure must increase to a minimum 7.0 bar (101.52 psi). If
7.0 bar (101.52 psi) is reached, open shut-off valve again im‐
mediately!
If pressure has increased:
– Replace the fuel filter if the fuel pump is OK but the pressure
relief valve in the fuel filter is faulty.
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pressure is measured through the Pressure Tester Kit -
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J538- -2- from the fuel delivery unit.


tion.
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– Remove the supply line -arrow- and wipe up the draining fuel
with a cleaning cloth.
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VAS5051/66- to the Pressure Tester Kit - VAS6550- and to the
– Switch on the Pressure Tester Kit - VAS6550- .
low the instructions from the vehicle diagnostic tester.
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proceed as follows:
Tester.
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pressure accumulates. The lever is perpendicular to the flow
direction.
If the Pressure No Longer Decreases, (Leak on the Engine Side).
Refer to ⇒ page 351 :
If the Pressure Drops Again (Leak on Fuel Tank Side):
Check for the leak on the fuel tank side. Proceed as follows:
– Check the fuel line leading to the fuel filter for leaks.
If no faults are found on fuel line:
– Check the pressure retaining valve in the fuel delivery unit.
Proceed as follows:
– Connect the Pressure Tester Kit - aVAS6550-n AG. Volksand

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– Close the shut-off valve -A- once the pressure has increased.
If the pressure drops:
– Replace the fuel delivery unit if the pressure retention valve in
the fuel pump is faulty. Refer to
page 338 .
If the pressure does not drop:
– The pressure retention valve in the fuel pump is OK. The pres‐
sure relief valve in the fuel filter is faulty. Replace the fuel filter.
If the Pressure No Longer Decreases (Leak on the Engine Side):
Note
there actually is a leak on the engine side.
– Remove the spark plugs. Open the shut-off valves -A and B-.
Activate the fuel pump with output diagnostic test mode.

Codes
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kswagen AG
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Adapter - 5 Pin - VAS5565- and the battery positive terminal

clamp in the engine compartment.
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uring container.
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Danger of spraying. Always wear protective eyewear and pro‐

tective clothing to prevent injuries and contact with skin. Hold
a container in front of the open connection of the pressure
gauge.

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pump is on.
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om
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thi
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– Repeat the fuel delivery rate test.
If the minimum delivery rate is now reached:
– Replace the fuel filter.
If minimum delivery rate is again not obtained:
debris.
Only when up to now no malfunction has been detected:
– Replace the fuel delivery unit.
supply):

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⇒ “8.3.8 Current Draw, Checking”, page 357 .
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Codes CCZA, CCZB, CDAA and CDAB
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– Select engine .
VAG1348/3A- and the Vehicle Diagnostic Tester - Test Adapt‐
er - 5 Pin - VAS5565- are connected to the fuel delivery unit.
• Battery charger is connected

4-Cylinder Fuel Injection Engine (1.8L and 2.0L. V
Engine,
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Test sequence: db
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Pressure Tester Kit - Hose 1 - VAS6550/1- to the fuel supply Prote
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line. Hold the Pressure Tester Kit - Hose 2 - VAS6550/2- into
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pump is on.
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page 319 .
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CCZA, CCZB, CDAA and CDAB”, page 329 .

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72 ; Rear Seats;Bench Seat, Removing and Installing . ht. Cop py
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tion.
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• Specified value: maximum 9 amps
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♦ If the malfunction in the fuel system only occurs sporadically,
the test can also be performed during a road test. A second
rrectness of i
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If the current draw is exceeded:

nform
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8.3.9 Low Side Fuel Pressures

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– Note the current engine speed (RPM) on the vehicle tachom‐
eter.
– Using the informations from the two previous steps, reference
the chart below for the correct fuel pressure.
Table Values Are the Desired Low Side Fuel Pressure in Bar (psi).
-1.1 4.33 10.1 15.5 21° 23.8 32.2 37.6 43.5 48.8
1° C °C 7° C 6° C C 9° C 2° C 7° C °C 9° C
(30° (39. (50. (60° (69. (75° (90° (99. (110 (120
F) 8° 3° F) 8° F) F) 8° .3° ° F)
F) F) F) F) F)
0 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
rpm bar bar bar bar bar bar bar bar bar bar
(43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
51 51 01 01 01 92 52 77 02 92
psi) psi) psi) psi) psi) psi) psi) psi) psi) psi)

-1.1 4.33 10.1 15.5 21° 23.8 32.2 37.6 43.5 48.8
1° C ° C 7°swCag6° en AC Colkswa9°
G. V C 2°
gen AG
doeCs 7° C ° C 9° C
(30° (39. by
Vo(50.
lk (60° (69. (75° (90° no(99.
t gu (110 (120
F) ris8°
ed 3° F) 8° F) F) 8° aran.3°
t ° F)
ut F) F) F) F) F)ee or
ho
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100 s3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
ce
le
0 bar bar bar bar bar bar bar bar bar bar
un
pt
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rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
itte
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51 51 01 01 01 92 52 77 02 92
erm
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200 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
h re
ole,
spec
rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
51 51 01 01 01 92 52 77 02 92
t to the co
300 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
rrectne
rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
51 51 01 01 01 92 52 77 02 92
ss
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400 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
form
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rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
om
n
51 51 01 01 01 92 52 77 02 92
c
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or
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500 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
pr
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rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
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51 51 01 01 01 92 52 77 02 92
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rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
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700 3.0 3.0 4.0 4.0 4.0 4.2 5.0 5.5 6.0 6.2
rpm (43. (43. (58. (58. (58. (60. (72. (79. (87. (89.
51 51 01 01 01 92 52 77 02 92

9 Fuel Supply, Servicing, Tiguan

⇒ “9.2 Fuel Level Sensor G, Removing and Installing”,
page 362 .
⇒ “9.3 Suction Jet Pump, Fuel Filter and Pressure Relief Valve,
Removing and Installing”, page 363
⇒ “9.4 Fuel Level Sensor 2 G169 , Removing and Installing”, page
365 .
⇒ “9.5 Fuel Pump Control Module J538 , Removing and Instal‐
ling”, page 366 .
⇒ “9.6 Fuel Pump, Checking”, page 367 .

stalling
Removing:
Note

clamps appropriate for the model type. n AG. Volkswagen AG do
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♦ Hose Clip Pliers - VAS6362- or the Hose Clip Pliers - ir se
d b ua
ran
VAG1921- are recommended for installing the spring clamps. tho tee
or
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Caution
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Conditions:
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• Fuel tank may be a maximum of 1/2 full. This ensures the

h re
hole
fuel level is below the fuel delivery unit flange. spec

es, in part or in w
t to the co
Note
rrectness of i
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nf
ercia
♦ If necessary, empty the fuel tank using the Fuel Extraction Unit
or
- VAS5190- .
m
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om

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– First pull on the 5-pin connector -1- without pressing the lock‐
ing mechanism to make sure it is connected securely. If the
connector was not connected correctly, it could cause a mal‐
function.
for damage.
– Disengage the connector -arrow- on the Fuel Pump Control

Module - J538- using the Elbow Assembly Tool - T10118- and
remove it.
AG. Volkswagen AG d
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WARNING yV
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The fuel line is under pressure. ut
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spec
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– Remove the supply line -2- and wipe up the draining fuel with
a cleaning cloth.
rrectness o
cial p
f inform
mer
atio
om
n
c
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fo
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T10202- . C py
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Caution cted agen
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– Lift the fuel delivery unit slightly and remove the seal through
the fuel tank opening.
9. Fuel Supply, Servicing, Tiguan 361

– Disconnect the fuel hoses on the delivery unit -arrows- and

remove the delivery unit out of the fuel tank.
Note
If the delivery unit is to be replaced then drain old delivery unit

before disposal.
Installing
– Connect the fuel hoses -arrows-. Make sure the fuel hoses
engage audibly and pull on them to make sure they are fas‐
tened securely.
– Installation of fuel delivery unit is the reverse of removal.
AG. Volkswagen AG d
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Note
spec
es, in part or in w
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♦ The fuel hoses are assigned to the respective connections.
♦ Always pull on the connectors to make sure they are fastened
securely.
rrectness of i
♦ Do not bend the Fuel Level Sensor - G- when inserting the fuel
l purpos
delivery unit.
♦ Insert the dry fuel delivery unit gasket into the opening in the
nform
ercia
fuel tank.
m
at
om
♦ Coat the seal with fuel only for installing the fuel delivery unit. ion
c
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or
♦ Pay attention to the position of the fuel delivery unit flange

his
ate
when it is installed: the tab -1- must point direction of travel.

do
priv
The fuel delivery unit flange can only be installed in this posi‐
um
for
en
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tion.
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9.2 Fuel Level Sensor G, Removing and In‐
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stalling
AG.
– Remove the fuel delivery unit. Refer to

page 360 .
♦ Welding wire (2 mm material strength)

– Bend an 80 mm long welding wire as shown.

Dimension -a-: 10 mm
Dimension -b-: 70 mm
Removing
– Disengage and remove the wire terminals for the fuel level
sensor.
– Press the welding wire -1- in direction of -arrow- into the open‐
ing under the sensor.
– At the same time, push the fuel level sensor -2- in direction of
-arrow- out of the guides.
Installing
– Insert the fuel level sensor in the guides on the fuel delivery
unit and push down until it engages.
– Connect connector and check for secure locking.
page 360 .
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9.3 Suction Jet Pump, Fuel Filter and Pres‐ ut ra
s a c
s
sure Relief Valve, Removing and Instal‐
ce
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spec

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Note
rrectness of i
♦ On AWD vehicles, the fuel must be pumped out of the Fuel

l purpos
Level Sensor 2 - G169- area and to the fuel delivery unit due
to the shape of the fuel tank. A suction jet pump pumps the
fuel from the left chamber to the right chamber in the fuel tank.
nf
ercia
orm
♦ The fuel delivery unit must be removed first in order to remove

m
atio
m
the suction jet pump.

o
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♦ The left flange consists of the suction jet pump, fuel filter,
thi
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sd
pressure relief valve and Fuel Level Sensor 2 - G169- . Only

iva
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the Fuel Level Sensor 2 - G169- can be replaced separately.

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♦ Only check the Fuel Level Sensor 2 - G169- if the engine shuts
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off due to low fuel but the fuel gauge indicates the tank is still
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1/4 full.
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Removing:
page 360 .
– Remove the left cover (when viewed from direction of travel)
from the Fuel Level Sensor 2 - G169- .
– First pull on the connector without pressing the locking mech‐
anism to make sure it connected securely. If the connector was
not connected correctly, it could cause a malfunction.
– Disconnect the connector -1-
olkfrom
swage the left flange. es n
o V t gu
by a
– Open the locking ringrisusing
ed the Wrench - Fuel Sending Unit -rante
T10202- . utho eo
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ss
– Lift the flange slightly and remove the gasket through the fuel
ce
le
un
tank opening.
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– Pull the flange together with the Fuel Level Sensor 2 - G169-
rm
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out of the flange.
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– Check the fuel lines for kinks and damage.
h re
hole
spec
es, in part or in w
t to the co
– Check the suction jet pump and the fuel tank for any contam‐
ination.
rrectness of i
Installing
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Caution
nform
mercia
Do not bend the Fuel Level Sensor 2 - G169- floater arm when
com
tion in
installing.
r
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s
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– Insert the flange together with the Fuel Level Sensor 2 - G169-
fo
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in the fuel tank. The tab on the flange faces in the direction of
n
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travel. Cop py
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– Route the fuel lines in the right chamber of the fuel tank so
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they are not kinked. Prote
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agen
– Insert a new, dry flange seal in the fuel tank opening. Only coat
the inner side that comes into contact with the flange with fuel.
– Pay attention to the Fuel Level Sensor 2 - G169- installation
position. Refer to
⇒ Fig. ““Installation Location of the Fuel Delivery Unit Flange
and Fuel Level Sensor 2 -G169- .”“ , page 299 .
– Make sure that the gasket is in the correct location.

– Tighten the locking ring using the Wrench - Fuel Sending Unit
- T10202- . Tightening specification: 110 Nm
– Connect the connector -1- and pull on it to make sure it is con‐

nected securely.
page 360 .
cedures. agen
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9.4 Fuel Level Sensor 2 - G169- , Removing
erm
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and Installing
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– Suction Jet Pump, Removing and Installing, Tiguan. Refer to
spec
⇒ “9.3 Suction Jet Pump, Fuel Filter and Pressure Relief
Valve, Removing and Installing”, page 363 .
t to the co
rrectne
♦ Welding wire (2 mm material strength)
– Bend an 80 mm long welding wire as shown.
ss o
Dimension -a-: 10 mm
cial p
f inform
Dimension -b-: 70 mm
mer
atio
m
Removing
o
n
c
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or
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– Release and remove the wire connector for the Fuel Level
te
sd
a
Sensor 2 - G169- -2-.

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– Press the welding wire -1- in direction of -arrow- into the open‐
en
ng
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ing under the sensor.
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– At the same time, slide the Fuel Level Sensor 2 - G169- -2- in
the direction of -arrow- from the guides.
Installing
– Insert the Fuel Level Sensor 2 - G169- into the guides and
push it down until it latches.
– Connect connector and check for secure locking.
– Install the suction jet pump. Refer to
⇒ “9.3 Suction Jet Pump, Fuel Filter and Pressure Relief
Valve, Removing and Installing”, page 363 .
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9.5 Fuel Pump Control Module - J538- , Re‐ au ra
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Note
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The Fuel Pump Control Module - J538- is located on the fuel tank.
hole
spec
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♦ Flat blade screwdriver (blade length 120 mm)
rrectness of i
Fuel Pump Control Module - J538- Component Location
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1 - Fuel Pump Control Module - J538- Bracket

2 - Fuel Pump Control Module - J538-
nform
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3 - Connector
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Removing
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– Remove the cover that is on the right side of the fuel delivery s
iva
do
unit when viewed in the direction of travel.
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AG.

function.
for damage.

– Push the screwdriver -2- into the opening in the bracket -1-
directly above the connector.
– Swivel the screwdriver in the direction of -arrow-.
– Press the screwdriver downward in the direction of -arrow- and
pull the control module out of the bracket at the same time.
– First pull on the connector without pressing the locking mech‐
anism to make sure it connected securely. If the connector was
not connected correctly, it could cause a malfunction.
– Disconnect the connector from the control module.

Installing
– Connect the connector -3- to the control module -2- and pull
on it to make sure it is connected securely.
– Slide the control module -2- into the bracket -1- until it engag‐
es.
The further installation is performed in reverse order of removal.
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9.6 Fuel Pump, Checking

wit
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⇒ “9.6.1 General Information and Special Tools”, page 367

spec
t to the co

rrectne

⇒ “9.6.6 Fuel Delivery Rate, Checking. Engine Codes CCTA”,
ss
page 374
o
cial p
f in
⇒ “9.6.8 Current Draw, Checking”, page 379

form
mer
atio
9.6.1 General Information and Special Tools

om
n
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or
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Note
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When replacing the fuel delivery unit, check the fuel tank for visi‐
Co
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ble contamination and clean if necessary. t. C rig
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Special tools and workshop equipment required cted agen
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VAG1348/3A-
♦ Analog/Digital Multimeter - FLU83III-
♦ Measuring container, three liter (3.17 quarts)

• Battery voltage at least 11.5 V
• Fuel pump fuse on the fuse panel OK. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
Test Sequence:
Note
tion.
before repeating the output diagnostic
agentest mode.
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spec
t to the co
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cial p
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mer
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Electronics and Output Diagnostic Test Mode (DTM)
one after another on the display.
– Press the right arrow button ► on the display until output di‐
agnostic test mode for the fuel pump electronics is reached.
RPM.
Note

If the Fuel Pump Does
wage
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n AG.Start:
Volkswagen AG
doe
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Vol t
– Removeethe d b bench seat. Refer to ⇒ Body Interior;
y gu
ara Rep. Gr.
72 ; Rear
thoris Seats;Bench Seat, Removing and Installing
nte
e .
or
au a
– Remove
ss the cover that is on the right side of the fuel delivery
c
ce

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Note
ility
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hole

spec
es, in part or in w
t to the co
connector was not connected correctly, check the fuel pump
rrectness of i
function again.
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nform
ercia
for damage.
m
at
om
ion

c
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or

his
ate
do
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– Connect the Analog/Digital Multimeter - FLU83III- to the wires

p
cum
or
-1- and -5- for the Vehicle Diagnostic Tester - Test Adapter -
f
en
ng
t.
5 Pin - VAS5565- .
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– Activate the fuel pump with output diagnostic test mode.
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• The voltage must rise during the output diagnostic test mode
to approximately 9 V.
ponent locations.
Voltage Supply OK:
page 360 .
– Check if the wiring between the flange and fuel pump is con‐
nected.
to
page 360 .

Test Conditions: agen
AG. Volkswagen AG d
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• Check the functionality of the fuel pump. Refer to byV gu
ara
e d
⇒ “9.6.2 Function and Power Supply, Checking”, page horis 368 . nte
eo
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Test Sequence ss c
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Note
erm
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ility
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spec
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WARNING
nform
ercia

m
at

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ion

c
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or

his
ate
do
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for
en
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– Disconnect the supply line (metal coupling) -2- and collect

n
t.
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draining fuel in with a cleaning cloth. C py
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– Replace the left flange with the pressure relief valve, suction
jet pump and fuel filter.

lkswage es n
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The pressure relief valve
ir se
d and the fuel filter are integrated in uthe
b ara
n
Fuel Level Sensor 2th-oG169- with the suction jet pump and cannottee o
be replaced individually.
ss
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ility
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⇒ “9.1 Fuel Delivery Unit, Removing and Installing”, spec

page 360 .
es, in part or in w
t to the co

rrectness of i
Engine Codes CCZA, CCZB, CCZC and

CCZD
l purpos
nform
ercia
Note
m
a
com
tio

n in
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te o

thi
s
iva
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pressure is measured through the Pressure Tester Kit -
Co
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VAS6550- and transferred to the Vehicle Diagnostic Tester .
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♦ This test can be a component of “Guided Fault Finding” if there
c by lksw
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is a DTC memory entry. It can also be started in the Vehicle Prote AG.
Diagnostic Tester under “Function and Component Selection”.


– Remove the cover that is on the right side of the fuel delivery
Note

function.
WARNING

nection point before looseningswhose
agen connections.
AG. Volkswagen AGCarefully
does
open the connection pointbto
y V release the pressure.
olk not
gu
ara
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th or
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ss
– Remove the supply line -2- and wipe up the draining fuel with
ce
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a cleaning cloth.
du
an
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
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or
his
ate
do
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for
en
ng
t.
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VAS5051/66- to the Pressure Tester Kit - VAS6550- and to the. Volkswage
AG
Vehicle Diagnostic Tester . ksw
agen
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– Make sure the drain is closed and the shut-offisvalves
ed
b are open. ran
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– Switch on the Pressure Tester Kit - VAS6550-
sa
ut . or
ac
s
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du
low the instructions from the vehicle diagnostic tester.
an
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If the fuel pressure test is done without “Guided Fault Finding”,
ility
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proceed as follows:
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t to the co
Tester.
rrectness of i
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♦ Motor
nf
ercia
orm
♦ Engine
m
atio
om
n in
c

or
thi
te
sd
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♦ Mechanical components
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♦ High pressure pump
f
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WARNING
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Test Conditions
Test Sequence:
If the pressure drops further:

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AG n AG d
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– Close the shut-off valve d by -B-
V on the pressure gauge as soon gu as
ara
pressure accumulates.
orise The lever is perpendicular to the flow nte
eo
direction. auth
ra
ss c
If the Pressure Drops Again (Leak on Fuel Tank Side):
ce
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nl
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du
an
Check for the leak on the fuel tank side. Proceed as follows:
itte
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ab
– Check the fuel line to the flange for leaks.
ility
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If no problem is found in the »outer« fuel lines, search for the leak
h re
in the fuel tank. Proceed as follows:
hole
spec
es, in part or in w
– Open the right and left flanges. Make sure all the line connec‐
t to the co
tions are connected and not leaking.
rrectness of i
– First replace the left flange with the pressure relief valve and
l purpos
fuel filter. Repeat the pressure retention test. If the leak is still
present, the check valve in the fuel pump is leaking. Replace
the fuel delivery unit.
nform
ercia
If the Pressure Stops Decreasing (Leak on the Engine Side):

m
at
om
ion
c
in t
or
Note
his
ate
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there actually is a leak on the engine side. C py
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– Remove the spark plugs. Open the shut-off valves
-A and B -. Activate the fuel pump with output diagnostic test
mode.
9.6.6 Fuel Delivery Rate, Checking. Engine

Codes CCTA
Test Conditions
• Voltage supply is OK.
• If driving is still impaired with the fuel tank is maximum 1/4 full,
then perform a fuel delivery test with the fuel tank only 1/4 full
or with very little fuel in the fuel tank.
Note


AG. Volkswagen AG d
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for damage.
rrectness of i
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nform
ercia

m
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tion in
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– Disconnect the supply line (metal coupling) -2- and collect

draining fuel in with a cleaning cloth.
Note


uring container.
WARNING
Danger of spraying when opening shut-off valve; wear protec‐

tive goggles and protective clothing to prevent injuries and
contact with skin. Hold a container in front of the open con‐n AG. Volkswagen AG do
nection of the pressure gauge. lkswage es n
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– Operate the Injection Rate Comparison sMeter
- Remote
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es, in part or in w
FLU83III- to wires -1 and 5- from the Vehicle Diagnostic Tester
t to the co
- Test Adapter - 5 Pin - VAS5565- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
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pump is on.
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Example: olks es n
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During test, a voltage of 10.5 Volts is measured.hoThis
ris results in a tee
minimum delivery quantity of approximately 1200
aut cm³/60 s. or
ac
ss
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ages.
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es, in part or in w
breather.
t to the co
rrectness of i
tions are connected and not leaking. Check the filter screen in
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the fuel delivery unit and fuel tank for visible contamination.
nform
ercia
– First replace the left flange with the pressure relief valve and
m
at
fuel filter. Repeat the fuel delivery rate test. If the fuel delivery
om
ion
quantity is still not reached, the fuel pump is faulty. Replace
c
in t
or
the fuel delivery unit.
his
ate
do
riv
p
cum
or

f
en
ng
t.
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supply):
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⇒ “9.6.8 Current Draw, Checking”, page 379 .
co lksw
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Codes CCZA, CCZB, CCZC, CCZD
Note


– Select engine .


VAG1348/3A- and the Vehicle Diagnostic Tester - Test Adapt‐
er - 5 Pin - VAS5565- are connected to the fuel delivery unit.
• Battery charger is connected
Test sequence:
WARNING

Fuel poses a risk of injury to wthe
ageeyes
n AG. Vand
olkswskin.
agen AG
doe
olks s no
Wear protective eyewear d b and protective clothing to avoid injury
yV gu t
ara
and contact with skin.rise Place a cleaning cloth around the con‐ nte
ho eo
nection point before
aut loosening hose connections. Carefully ra
c
ss
ce
le
un
pt
an
d
itte
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rm
– Remove the fuel line -2- and wipe up the draining fuel with a
ab
pe
ility
cleaning cloth.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Connect the Pressure Tester Kit - VAS6550- using the Pres‐

a
com
tio
sure Tester Kit - Hose 2 - VAS6550/2- to the flange. Hold the

n in
r
Pressure Tester Kit - Hose 1 - VAS6550/1- into a measuring

te o
thi
container.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
– Press the Injection Rate Comparison Meter Kit - Remote Ca‐ Cop py
t. rig
ble - VAG1348/3A- and slowly close the shut-off valve yri
gh by
ht
-arrow- until 4 bar (58 psi) displays on the pressure gauge.
op Vo
by c lksw
From this point on do not move the position of the shut-off cted agen
Prote AG.
valve.



pump is on.
Example:
ages.
breather.
tions are connected and not leaking. Check the filter screen in
the fuel delivery unit and fuel tank for visible contamination.
If no error can be found: n AG. Volkswagen A
G do
wage es n
– First replace bthe olks
y V left flange with the pressure relief ua valve and
ot g
fuel filter. rRepeat
ised the fuel delivery rate test. If the fuel
ran delivery
tee
quantity uthis
o still not reached, the fuel pump is faulty. Replace
or
the fuel
ss delivery unit.
a ac
ce
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nl
pt
du
an

itte
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erm

ab
ility

ot p
wit
CCZA, CCZB, CCZC and CCZD”, page 371 .

, is n
h re
hole
spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
ercia

m
at
function.
om
ion
c
in t

or
his
ate
do
riv
p
for damage.
um
for
en
ng
t.
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Cop py
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cted agen
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– Connect the current probe -A- to the red wire with the word
“current probe” on the Vehicle Diagnostic Tester - Test Adapt‐
er - 5 Pin - VAS5565- .
– Start the engine and run at idle speed.
• Specified value: maximum 16 amp
Note
♦ If malfunction in fuel system is sporadic, the test can also be
performed during a road test, but a second person is required.
If the Current Draw Is Exceeded: n AG. Volkswagen AG do

lkswage es n
– Replace the fuel delivery unitd bify Vthe
o
fuel pump is faulty. Refer ot gua
to or
ise
ran
tee
⇒ “9.1 Fuel Delivery Unit,
au Removing and Installing”,
th or
ac
page 360 . ss
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
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

10 Electronic Engine Output Control

(EPC)
⇒ “10.1 Overview - Accelerator Pedal Module”, page 381 .
⇒ “10.2 Accelerator Pedal Module, Removing and Installing”,
page 381 .
10.1 Overview - Accelerator Pedal Module
1 - Connector
❑ Black 6-pin
2 - Accelerator Pedal Position
Sensor - G79- with Accelerator
Pedal Position Sensor 2 -
G185-
❑ Not adjustable
❑ The accelerator pedal
position sensor trans‐
mits the actuation by the
driver to the engine con‐
trol module
❑ -A- Openings for Re‐
lease Tool - T10238-
❑ Removing and instal‐ gen AG
. Volkswagen AG
does
swa
ling. Refer to y Volk not
gu
⇒ “10.2 Accelerator risedb ara
nte
Pedal Module, Remov‐
ut
ho eo
ra
ing and Installing”,
ss a page c
381 .
ce
e
nl
pt
du
an
3 - Bolt
itte
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erm
ab
❑ 10 Nm
ility
ot p
wit
4 - Cap
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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
10.2 Accelerator Pedal Module, Removing

do
priv
cum
or
and Installing
f
en
ng
t.
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op
C py
t. rig
gh ht
yri by
♦ Accelerator Pedal Module Release Tool - T10238-
op Vo
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cted agen
Prote AG.
10. Electronic Engine Output Control (EPC) 381

Removing
– Remove the steering column cover -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
– Pry out the cap -3- with a screwdriver.
itte
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erm
ab
ility
ot p
wit
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– Disconnect the connector -1- -arrow- from the accelerator
h re
pedal module.
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
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te
sd
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f
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ng
t.
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op
– Slide the Accelerator Pedal Module Release Tool - T10238- C py
t. rig
as shown, into the designated openings for it until it stops and
gh ht
pyri by
remove accelerator pedal module.
o Vo
by c lksw
cted agen
Prote AG.
Note
The release tool must be slightly raised and then lightly pushed
in at an angle for the Tiguan.
Installing

– Connect the connector -1- to the accelerator pedal module

-4-. Lock the connector -arrow-.
– Press accelerator pedal module onto the retaining pin -5-.
– Insert the centering pin -6- into the hole on the underbody.
olks
wage es n
ot g
V
by ua
– Secure the accelerator pedal module with theris bolt -2-
ed and in‐ ran
tee
stall the cap -3-. utho or
a ac
ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Install the cover on the steering column.
ss o
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f
Tightening Specification:
inform
mer
Component Nm
atio
om
n
Accelerator pedal module to body 10
c
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or
n thi
te
sd
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pr
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fo
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t.
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Cop py
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rig ht
py by
co Vo
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cted agen
Prote AG.
10. Electronic Engine Output Control (EPC) 383

11 EVAP Canister System, Passat, CC

and Tiguan
⇒ “11.2 Overview - EVAP Canister System”, page 386 .
⇒ “11.4 Fuel System, Checking for Leaks”, page 390 .
11.1 Overview - EVAP Canister System, En‐

gine Codes BZB, CAWA, CAWB,
CGYA, CCZA, CCZB, CCZC, CCZD,
CDAA, and CDAB
Note
♦ Hose connections are secured with either spring or hose

clamps.
The connector couplings for fuel, vacuum and vent lines are color
coded. There is either a colored dot on the connector coupling or
the release button is the corresponding color.
Connector coupling Color coding onAthe
G. Voconnector
lkswagen AG
couplinglkswagen does
no
o t gu
yV
Fuel supply Black
ris
ed
b ara
nte
o eo
Fuel return au Blue
th
ra
ss c
Ventilation White, beige
ce
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un
pt
Vacuum Green
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
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t.
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Cop py
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by c lksw
cted agen
Prote AG.

1 - EVAP Canister
❑ Installed location: inside
the right rear wheel
housing
❑ To remove, remove the
bolts and pull the EVAP
canister downward out
of the mount.
2 - Pressure Retaining Valve
with Connecting Hose
❑ To remove, grasp circlip
(gray) and pull upward
3 - From the fuel tank
4 - Vent Line AG. Volkswagen AG d
agen oes
❑ to the EVAP Canister olksw not
y V gu
Purge Regulator Valve ise
d b ara
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1 - N80- -item 6- uthor eo
⇒ Item 6 (page 385) ss a ra
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5 - Vent Line
ility
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❑ From EVAP canister
is n
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-item 1-
ole,
spec
⇒ Item 1 (page 385)
t to the co
6 - EVAP Canister Purge Reg‐
ulator Valve 1 - N80-
rrectne
❑ The valve is closed
when the ignition is off
ss
❑ Valve is activated
o
cial p
f i
(pulsed) by the engine
nform
control module when
mer
the engine is warm

atio
om
n
c
7 - Connecting Hose
i
or
n thi
te
sd
❑ To the Intake Manifold

iva
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ng
t.
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8 - 10 Nm
Co
Cop py
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Prote AG.
11. EVAP Canister System, Passat, CC and Tiguan 385

11.2 Overview - EVAP Canister System

⇒ “11.2.1 General Information”, page 386 ‘
⇒ “11.2.2 Overview - EVAP System”, page 386
⇒ “11.2.3 Overview - EVAP Canister System, Vehicles with Ad‐
ditional Filter”, page 388
Note

clamps.
Connector Coupling Color Coding on the Connector
Coupling
Fuel supply Black
Fuel return Blue
Vacuum Green
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
Some vehicles have an additional filteroriinstalled
se
on the EVAP nte
eo
canister. aut
h
ra
ss c
ce
e
nl
Overview - EVAP System. Refer to

pt
du
an
⇒ “11.2.2 Overview - EVAP System”, page 386 .

itte
y li
erm
ab
Overview - EVAP Canister System, Vehicles with Additional Fil‐

ility
ot p
ter. Refer to
wit
, is n
⇒ “11.2.3 Overview - EVAP Canister System, Vehicles with Ad‐

h re
hole
ditional Filter”, page 388 .

spec
es, in part or in w
11.2.2 Overview - EVAP System

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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Cop py
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by c lksw
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Prote AG.

1 - Bolts
2 - Leak Detection Pump -
V144-
3 - Vacuum Line
4 - Clamp
5 - Connecting Hose
❑ EVAP canister / Leak
Detection Pump - V144-
6 - Vacuum Hose
7 - Connecting Hose
❑ Leak Detection Pump -
V144- / air filter
8 - Air Filter
9 - Nut
❑ 10 Nm
10 - EVAP Canister
housing
canister downward out
of the mount.
11 - Vent Line
olkswagen AG
❑ To the EVAP en AG. V
agCanister does
lksw not
PurgebyRegulator
V o Valve gu
ara
1 r-isN80-
ed
nte
ho eo
❑s autClipped to the fuel tank ra
c
s
12 - Vent Line
ce
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pt
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an
❑ From the fuel tank

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ility
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c
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or
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ate
do
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cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
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11.2.3 Overview - EVAP Canister System, Vehicles

agen
with
AG. VolksAdditional
wagen AG
do
Filter
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Vol ot g
d by ua
ran
e
1 - Leak Detection Pump - tho
ris tee
or
V144- au ac
ss
ce
le
2 - Vacuum Line
un
pt
an
d
itte
3 - Vacuum Hose
y li
erm
ab
ility
4 - Connecting Hose
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5 - Clamp
h re
ole,
spec
6 - Vent Line urposes, in part or in wh
t to the co
7 - Clip
rrectne
8 - Connecting Hose
❑ Leak Detection Pump -
ss
V144- / air filter
o
cial p
f in
9 - Bolt
form
mer
atio
10 - Air Filter
om
n
c
i
11 - Auxiliary Filter
or
n thi
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sd
va
12 - Nut
i
o
pr
cum
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fo
❑ 10 Nm
en
ng
t.
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op
13 - Vent Line C py
t. rig
gh ht
❑ To the EVAP Canister yri
p by
o Vo
Purge Regulator Valve
by c lksw
cted agen
1 - N80-
Prote AG.

14 - Connecting Hose
15 - EVAP Canister
housing
canister downward out of the mount.
16 - Bolts
11.3 Fuel Tank Ventilation, Checking, Engine

Codes BZB, CAWA, CAWB, CGYA,
CCZA, CCZB, CCZC, CCZD, CDAA,
and CDAB

♦ Hand Vacuum Pump - VAS6213-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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h re
hole
Test Sequence
spec
es, in part or in w
– Remove the breather line -2-. Press the release button. (color
t to the co
identification: white)
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Connect the Hand Vacuum Pump - VAS6213- to ventilation
en
ng
t.
yi Co
line as illustrated. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Set the slide ring -1- of the Hand Vacuum Pump - VAS6213-
to position -A- for “vacuum”.
– Operate the Hand Vacuum Pump - VAS6213- several times.
No vacuum should be built up.

– Seal the vent hole on EVAP canister -arrow- and operate vac‐
uum pump again several times. A vacuum must form.
11.4 Fuel System, Checking for Leaks

⇒ “11.4.1 Fuel System, Checking for Leaks”, page 390
⇒ “11.4.2 Fuel System Leak Detection”, page 394
⇒ “11.4.3 EVAP System, Function Overview”, page 395
⇒ “11.4.4 Leak Detection Pump V144 , Checking Vacuum Sup‐
ply”, page 396
11.4.1 Fuel System, Checking for Leaks

wage es n
♦ Evaporative Emissions Tester - KLI9210-
yV
olks ot g
ua
b
ed ran
♦ Evaporative Emissions Tester - tAdapter
ho
ris 55 - KLI9210/55-1- tee
or
au ac
♦ Vehicle Diagnostic Tester ss ce
le
un
pt
an
d
itte
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rm
ab
pe
ility

ot
wit

, is n
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hole

spec
es, in part or in w
Coupling
t to the co
Fuel supply Black

Fuel return Blue
rrectness of i

l purpos
Vacuum Green
Test Conditions:
nform
ercia
• The Leak Detection Pump - V144- detected a leak.

m
a
com
tio
• Guided Fault Finding was performed using the Vehicle Diag‐

n in
r
te o
nostic Tester .
thi
s
iva
do
Evaporative Emissions Tester - KLI9210- Preparation:

r
rp
cum
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
o
by c lksw
Depending on the version, the appearance of the Evaporative Prote
cted AG.
agen
Emissions Tester - KLI9210- may vary.
– Check on the Evaporative Emissions Tester - KLI9210- wheth‐

er there is enough fluid in the smoke generator.

– Set valve -D- to “Hold”.

– Open the nitrogen bottle -H-. agen
AG. Volkswagen AG d
oes
olksw not
– Connect the measuring hose -G-eto d b the self-test connection
yV gu
ara
-B-. horis nte
eo
aut ra
– Set valve -D- to “Test”. ss c
ce
e
nl
– Using the pressure reducer -J-, adjust the pressure to 10 in.
pt
du
an
H2O (25 mbar) on. itte
y li
erm
ab
ility
ot p
wit
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– The pressure must now be maintained a minimum of 2 mi‐
h re
hole
nutes. If the pressure is not maintained, check the tester.
spec
es, in part or in w
Fuel System, Checking for Leaks:
t to the co
rrectness of i
l purpos
– Connect the Evaporative Emissions Tester - Adapter 55-1 -
nform
ercia
KLI9210/55-1- to the vent line -A-. (color identification: white)

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Connect the measuring hose -G- from the Evaporative Emis‐

sions Tester - KLI 9210- to the Evaporative Emissions Tester
- Adapter 55-1 - KLI9210/55-1- .


– Start the engine and let it run at idle speed.
– Select Guided Functions on the Vehicle Diagnostic Tester .
– Select the guided function “Checking tank ventilation system
for leaks”.
– Start the test.
– Watch the pressure gauge on the Evaporative Emissions
Tester - KLI9210- during the test.
• The Leak Detection Pump - V144- must pump the fuel system
up to minimum 7 in. Inflate H2O (18 mbar).
The minimum pressure is not reached, but the pressure reached
does not decrease:
– Switch ignition off and perform pressure retention test
⇒ page 392 . If no drop in pressure is detected: Check the
vacuum supply from the Leak Detection Pump - V144- . Refer
to ⇒ page 396 .
The minimum pressure is not reached and the pressure reached
decreases immediately:
– Clamp off the hose to the EVAP Canister Purge Regulator

Valve 1 - N80- with a hose clamp -arrow-.
– Repeat the test. If the minimum pressure is now reached: Re‐
place the EVAP Canister Purge Regulator Valve 1 - N80- .
If the minimum pressure is not reached again and the pressure
that is reached decreases immediately:
– Leak in fuel system: perform “leak test in fuel system”. Refer
to ⇒ page 394 .
AG. Volkswagen AG d
agen
If the Minimum Pressure Is Reached, Switch Ignition Off. Volksw
oes
not
gu
d by ara
The valve in the Leak Detection Pump - V144- is now closedorand
ise nte
eo
the pressure is maintained. aut
h
ra
ss c
– Observe the pressure gauge:
ce
e
nl
pt
du
an
If the pressure does not decrease, perform a pressure retention
itte
y li
erm
test to locate any possible pinhole leaks ⇒ page 392 .

ab
ility
ot p
wit
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If the pressure decreased, clamp off hose to EVAP Canister h re

Purge Regulator Valve 1 - N80- with a hose clamp -arrow-.
hole
spec
es, in part or in w
– If the pressure now stops decreasing, replace the EVAP Can‐

t to the co
ister Purge Regulator Valve 1 - N80- .

If the pressure still decreases, perform “leak test in fuel system”.
rrectness of i
Refer to ⇒ page 394 .

l purpos
Pressure Retention Test

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Set valve -D- to “Test”. Increase the current pressure until it

reaches 10 in. H2O (25 mbar).
– Pay attention to the pressure gauge -C- and the flow meter
-E-. Let the flow rate decrease and if the pressure builds to 10
in. H20 (25 mbar), the fuel system is filled.
Note
Depending on the level in the fuel tank, this procedure may take
up to three minutes.
– After the pressure has stabilized, set valve -D- to “Hold”.

• After five minutes the pressure must not drop below 8 in. H2O
(20 mbar).
If the Pressure Is Not Maintained for Five Minutes, the Leak
Should Be Localized as Follows:
AG. Volkswagen AG d
agen oes
olksw not
– First check the EVAP Canister Purge Regulator ed byValve
V
1 - N80- gu
ara
for leaks. To do this, clamp off the hose tohothe EVAP Canister
ris nte
eo
Purge Regulator Valve 1 - N80- with a ahose
ut clamp -arrow-. ra
c
ss
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
rrectne
– Repeat pressure test by resetting the valve -D- to “Test”.
– Observe the pressure gauge and flow meter. The fuel system
s
is filled if the flow quantity decreases and the pressure increa‐
s o
cial p
ses to 10 in. H2O (25 mbar).
f inform
mer
– After the pressure has stabilized, set valve -D- to “Hold”. atio
m

o
n
c
i
or

thi
te
sd
va

i
o
pr
cum
Refer to ⇒ page 394 .

r
fo
en
ng
t.
yi Co
After completing the work, perform the “Check tank ventilation Cop py
system for leaks” guided function with the Vehicle Diagnostic ht. rig
rig ht
Tester .
py by
co Vo
by lksw
cted agen
Prote AG.

11.4.2 Fuel Systemn ALeak Detection

G. Volkswagen A
age G do
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Test Conditions: by Vol ot g
ua
ed ran
• The procedure oris “Fuel System, Checking for Leaks” is per‐tee
h
ut or
formed.ss aRefer to ac
ce
le
un
pt
an
• The Evaporative Emissions Tester - KLI9210- must be con‐
d
itte
y li
nected to the vehicle with the Adapter Hose - KLI9210/55-1- .
erm
ab
ility
ot p
– Connect the Evaporative Emissions Tester - KLI9210- to the
wit
is n
vehicle battery.
h re
ole,
spec
– Remove the right rear wheel housing liner.
t to the co
rrectne
– Clamp off the hose between the Leak Detection Pump - V144-
and air filter -arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Set valve -D- to “Test”.

(20 mbar).
– If the pressure no longer decreases, replace the Leak Detec‐
tion Pump - V144- .
If the Pressure Is Not Maintained for a Minimum of Five Minutes
or If No Pressure Is Built up, Localize the Leak as Follows:
– Fill the fuel system with smoke
wage by setting valved-D-
n AG. Volkswagen AG o to “Test”.
es ks not
Vol g
– While fuel system is ed being filled, press smoke generator button
by ua
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-I- for approximately
thoris one minute. tee
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The fuel system
ss is now under pressure and filled with smoke. c
ce
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pt
– Check all fuel system lines and hoses for escaping smoke.
du
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Also check the fuel filler cap.
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Note
h re
hole
spec
♦ Illuminate components and hoses with a strong flood light, the
es, in part or in w
t to the co
smoke will be more visible.
♦ To check for leaks at accessible locations, also use ultrasonic
measuring device or commercially available leak detection
spray. rrectness of i
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♦ Depending on how long fault finding lasts, the smoke gener‐

ator button may need to be pressed again. This ensures there
nf
ercia
is enough smoke present in the fuel system.

orm
m
♦ To check fuel pump and fuel filter flange, the assembly open‐
atio
m
ings in the vehicle interior must be opened. Refer to Vehicle

o
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c
Diagnostic Tester .
or
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te
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– Replace the leaking hoses or components.

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After completing the work, perform the “Check tank ventilation
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system for leaks” guided function with the Vehicle Diagnostic
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11.4.3 EVAP System, Function Overview

1 - EVAP Canister
2 - Evaporative Emissions
Tester - Adapter 55 -
KLI9210/55-1- Component Lo‐
cation
❑ During the leak test in
fuel system
4 - Vent Line . Volkswagen AG
gen AG does
❑ Throttle Valve ControlVolkswa not
Module - J338- ed by gu
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5 - Solenoid Valve auth eo
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❑ For the Leak Detection
ce
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nl
Pump - V144-
pt
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6 - Vacuum Line
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7 - Air Filter
h re
hole
spec
es, in part or in w
Pump - V144-
t to the co
V144-
rrectness of i
9 - Fuel Tank
l purpos
10 - Cap
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11.4.4 Leak Detection Pump - V144- , Check‐
ht
pyri by
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ing Vacuum Supply cted agen
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♦ Turbocharger Tester Kit - VAG1397A-
♦ T-Connection - 251 201 346-
♦ 6 mm hose
Note
Leak Detection Pump - V144- component location: inside the right

rear wheel housing under the wheel housing liner.
– Remove the right rear wheel the and wheel housing liner.

– Remove the vacuum line -1- from the Leak Detection Pump -
V144-
– Connect the Turbocharger Tester Kit - VAG1397A- with the T-
piece and 6 mm hose between the vacuum line -1- and the
Leak Detection Pump - V144- -2-.
– Switch on the measuring range I (absolute pressure meas‐
urement).
– Connect the Vehicle Diagnostic Tester and start the engine.
for leaks”.
– Start the test.
– During the test, pay attention to the display on the Turbo‐
charger Tester Kit - VAG1397A- .
• The pressure must pulsate and must not rise above 0.700 bar
(10.15 psi) (absolute pressure) during the test.
– If the pressure rises above 0.700 bar (10.15 psi) during the
test, the vacuum supply is too low. Check vacuum line to the
intake manifold for kinks or blockages.
lkswage es n
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ir se tee
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a ac
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es, in part or in w
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rrectness of i
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ate
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12 EVAP Canister System, Golf, Eos

and Scirocco with Engine Codes CA‐
WA, CAWB, BZB, CGYA, CCZA,
CCZB and CDAA
⇒ “12.1 Overview - EVAP System”, page 398 .
⇒ “12.2 Fuel Tank, Checking Ventilation”, page 399 .
12.1 Overview - EVAP System
Note

clamps.
Connector coupling Color coding on the connector
coupling
Fuel supply Black
Fuel return Blue
Vacuum Green
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
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1 - EVAP Canister
❑ Component location: in
the engine compart‐
ment on the right side
2 - Pressure Retaining Valve
with Connecting Hose
3 - Connecting Hose
4 - 10 Nm
❑ The valve is closed
when the ignition is off
❑ Valve is activated
(pulsed) by the engine
control module when
the engine is warm
6 - Connecting Hose
7 - Bracket
❑ For the EVAP canister
8 - Vent Hole
AG. Volkswagen AG d
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12.2 Fuel Tank, Checking Ventilation

, is n
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hole
spec

es, in part or in w
t to the co

rrectness of i
♦ Pressure Tester Kit - Adapter Set - Fitting - VAS6550/3-1-

l purpos
Test conditions:
• The ignition must be off.
nf
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12. EVAP Canister System, Golf, Eos and Scirocco with Engine Codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB and CDAA 399
Test sequence:
– Remove the breather line -1-.
– Connect the Hand Vacuum Pump - VAS6213- with the Pres‐

sure Tester Kit - Adapter Set - Hose 1 - VAS6550/3-1- to the
EVAP canister vent line.
– Set the slide ring -1- on the Hand Vacuum Pump - VAS6213-
in position -A- for “vacuum”.
No vacuum should be built up.
If a vacuum forms:
– Check the vent hole on the EVAP canister -8- -item 8- AG. Volkswagen AG d
agen
⇒ Item 8 (page 399) for contamination and clean it if neces‐ Volksw
oes
not
sary. ed by gu
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If no vacuum forms: ho eo
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pt
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– Seal the breather hole -arrow- and operate the vacuum pump
erm
ab
several times again. A vacuum must form.

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If no vacuum forms:
h re
hole
spec
– Clamp off the hose between the EVAP canister and EVAP
es, in part or in w
Canister Purge Regulator Valve 1 - N80- -item 5-

t to the co
⇒ Item 5 (page 399) .

– Operate the vacuum pump again a few times.
rrectness of i
If the vacuum increases: Replace the EVAP Canister Purge Reg‐

l purpos
ulator Valve 1 - N80- .

If there is no vacuum: replace the EVAP canister
nf
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AG.
AG. Volkswagen A
13 EVAP System,
Vol
ksw
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⇒ “13.1 Overview Plan
or
ise - EVAP System”, page 401 . tee
h
ut or
⇒ “13.2 Overview
ss
a
- EVAP System, Golf”, page 403 . ac
ce
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nl
⇒ “13.3 Overview - EVAP System, Eos”, page 404 .
pt
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⇒ “13.4 EVAP Canister, Removing and Installing”, page 405 .
erm
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ility
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⇒ “13.5 Leak Detection Pump V144 , Removing and Installing,
wit
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Golf”, page 406 .
h re
hole
spec
⇒ “13.6 Leak Detection Pump V144 , Removing and Installing,
es, in part or in w
Eos”, page 407 .
t to the co
13.1 Overview Plan - EVAP System
rrectness of i
l purpos
Note
nform
ercia

m
at
om
clamps.
ion
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ate
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coded. There is either a colored dot on the connector coupling or C py
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Coupling
Fuel supply Black
Fuel return Blue
Vacuum Green
13. EVAP System, Rabbit and Eos 401

1 - Separating Point
❑ In the front of the engine
compartment on the
right side, under the
coolant expansion tank
2 - Vent Line
❑ White
❑ From EVAP canister to
the EVAP Canister
1 - N80-
❑ Installed position: on the
right side the underbody
❑ Secured on the fuel
tank.
3 - Vent Line agen
AG. Volkswagen AG d
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❑ Green by Vo gu
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❑ From the enginehto oristhe nte
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Leak Detection s a Pump -
ut ra
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V144- . s
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❑ Installed position: on the
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right side the underbody
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❑ Secured on the fuel
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tank.
wit
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hole
❑ In front of the fuel tank spec

es, in part or in w
t to the co
on the right side, near
the fuel filter
5 - Filler Neck
rrectness of i
6 - Vent Line
l purpos
❑ From the filler neck to

the EVAP canister
nform
ercia
7 - Air Filter
m
at
om
❑ For the Leak Detection Pump - V144-

on
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8 - Leak Detection Pump - V144-

his
ate
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❑ Component location: under the wheel housing liner inside right rear wheel housing
p
cum
for

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⇒ “13.5 Leak Detection Pump V144 , Removing and Installing, Golf”, page 406 .
Co
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❑ Fuel System, Checking for Leaks. Refer to ⇒ “13.7 Fuel System, Checking for Leaks”, page 407
gh ht
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9 - Connecting Line Prote
cted AG.
agen
❑ From the Leak Detection Pump - V144- to the EVAP canister.

❑ Clip onto the bracket.
10 - EVAP Canister
❑ Installed location: in the bottom of the spare tire well
❑ Removing and installing. Refer to ⇒ “13.4 EVAP Canister, Removing and Installing”, page 405 .
❑ On the back right of the fuel tank

12 - Turbocharger
13 - Brake Booster
14 - Vacuum Pump
15 - Check Valve
❑ Installation position: The arrow points in the flow direction
16 - EVAP Canister Purge Regulator Valve 1 - N80-
❑ Checking. Refer to Vehicle Diagnostic Tester .
17 - Check Valve
❑ Allocations for different versions. Refer to Parts Catalog.
18 - Throttle Valve Control Module - J338-
⇒ “2.14 Throttle Valve Control Module J338 , Removing and Installing”, page 484 .
19 - Intake Manifold
13.2 Overview - EVAP System, Golf
1 - Fuel Tank
2 - Vent Line
❑ Behind the wheel hous‐
ing liner
3 - Vent Line n AG. Volkswagen AG do
swage es n
❑ On the underbody
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4 - Vent Line thoris e or
au
❑ To thessEVAP Canister ac
ce
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pt
1 - N80-
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❑ To remove, press the re‐

erm
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lease button
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5 - 8 Nm
h re
hole
spec
6 - EVAP Canister
es, in part or in w
❑ Installed location: in the

t to the co
bottom of the spare tire

well
rrectness of i

ling. Refer to
l purpos
⇒ “13.4 EVAP Canister,

ling”, page 405 .
nform
ercia
7 - Connecting Line
m
at
om
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8 - Connecting Line
at
do
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❑ Behind the wheel hous‐

um
for
ing liner
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9 - 3 Nm
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10 - Air Filter cop Vo
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Pump - V144-

12 - Bracket
❑ For the Leak Detection Pump - V144-
13 - Bolt
❑ 2 Nm
14 - Nut AG. Volkswagen AG d
agen
❑ 6 Nm Volksw
oes
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15 - Leak Detection Pump oris-e V144- nte
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th
❑ Component location:
ss au
under the wheel housing liner inside right rear
ra
c wheel housing
ce
le
un
pt
⇒ “13.5 Leak Detection Pump V144 , Removing and Installing, Golf”, page 406 .
an
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❑ Fuel System, Checking for Leaks. Refer to ⇒ “13.7 Fuel System, Checking for Leaks”, page 407
erm
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16 - Connector
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17 - Vacuum Line
ole,
spec
❑ From the intake manifold
t to the co
13.3 Overview - EVAP System, Eos
rrectness
1 - Hose Bracket
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f in
2 - Vent Line
form
mer
❑ To remove and install, atio

m
remove the bumper

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3 - Air Filter
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Pump - V144-
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4 - Nut C py
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❑ 6 Nm yri
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5 - Bracket
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Pump - V144-
6 - Bolt
❑ 3 Nm
7 - Retaining Plate
8 - Rubber Bushing
9 - Bolt
❑ 8 Nm
V144-
❑ Installed location: be‐
hind the right rear wheel
ling. Refer to
⇒ “13.5 Leak Detection
Pump V144 , Removing
and Installing, Golf”,
page 406 .
❑ Fuel System, Checking
for Leaks. Refer to

⇒ “13.7 Fuel System,

Checking for Leaks”, page 407
11 - Hose Clamp
13 - Vent Line
❑ Behind the wheel housing liner
14 - Fuel Tank
15 - Vent Line
❑ To the EVAP Canister Purge Regulator Valve 1 - N80-
❑ To remove, press the release button
16 - Vent Line
17 - EVAP Canister
❑ Installed location: in the bottom of the spare tire well
❑ Removing and installing. Refer to ⇒ “13.4 EVAP Canister, Removing and Installing”, page 405 .
18 - Connecting Line
❑ EVAP canister / Leak Detection Pump - V144-
19 - Vacuum Line
20 - Bolt AG. Volkswagen AG d
agen oes
ksw
❑ 2 Nm by
Vol not
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13.4 EVAP Canister, Removing and Instal‐
s
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un
pt
ling
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h re
ole,
spec
Removing:
t to the co

– Remove the heat shield -arrows-.
rrectne
– Place the Engine and Gearbox Jack - VAS6931- under the

rear axle for support.
ss o
cial p
f inform
mer
atio
om
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c
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or
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te
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cted agen
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– Loosen the bolts on the rear axle -arrows- approximately 20

mm.
– Slowly lower the rear axle using the Engine and Gearbox Jack
- VAS6931- .
– Remove the vent lines -A-.

– Remove the bolts -B-.
Note
A reinforcement plate is installed on the Eos. Use the T Bar And

Socket - 10mm - 3185- to loosen and tighten the bolts -B-.
lkswage es n
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byV ua
– Release the retaining strapsorinisedirection of -arrow A- using a
d ran
tee
screwdriver. Rotate EVAPaucanister approximately 90° clock‐
th or
ac
wise in direction of -arrow
ss B- and remove the EVAP canister.
ce
le
un
pt
Installing:
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– Connect breather lines until they engage audibly.

wit
is n
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– Install the rear axle. Refer to ⇒ Suspension, Wheels, Steering;

ole,
spec
Rep. Gr. 42 ; Drive Axle .

t to the co
Tightening Specification
Component Nm
rrectne
EVAP canister to body 8

ss o
13.5 Leak Detection Pump - V144- , Remov‐

cial p
f inform
ing and Installing, Golf

mer
atio
m
Removing:
o
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c
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or
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e

t
sd
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– Disconnect the vacuum line -1-. t. Cop py
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– Disconnect the connector -2-. pyri by
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cted agen
– Press the release button and disconnect the breather line Prote AG.
-3-.
– Remove the nuts -arrows-.

– Disengage the diagnostic pump with bracket.

Installing:
• The breather line -3- must engage audibly.
– Install the right rear wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Hous‐
ing Liner, Removing and Installing .
Tightening Specifications. Refer to
⇒ “13.2 Overview - EVAP System, Golf”, page 403 .
13.6 Leak Detection Pump - V144- , Remov‐

ing and Installing, Eos
Removing:
– Remove the vacuum line -1-, the ventilation line -2- and the
ventilation line -3-.
– Remove the nuts -arrows-.
– Remove the pump with bracket and disconnect the connector.
Installing:
♦ Before installing the pump with the bracket, connect the con‐
nector.
♦ The vent line -2- must engage audibly.
olkswagen AG
en AG. V
Tightening Specifications. Refer to olks
wag does
not
⇒ “13.3 Overview - EVAP System, Eos”, page 404ed.by V gu
ara
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13.7 Fuel System, Checking for Leaks
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⇒ “13.7.1 Fuel System, Checking for Leaks”, page 407 ab

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⇒ “13.7.2 Fuel System Leak Detection”, page 411 h re

hole
⇒ “13.7.3 EVAP System, Function Overview”, page 412

spec
es, in part or in w
⇒ “13.7.4 Leak Detection Pump V144 , Checking Vacuum Sup‐

t to the co
ply”, page 413
13.7.1 Fuel System, Checking for Leaks

rrectness of i
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♦ Evaporative Emissions Tester - KLI9210-
nform
ercia
♦ Evaporative Emissions Tester - Adapter 55 - KLI9210/55-1-

m
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ate
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Connector Coupling Color Coding on the Connector yri
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Coupling
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Fuel supply Black
Fuel return Blue

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Connector Coupling ColorswCoding
agen
AG on the Connector
en AG
does
Volk
Coupling not
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Ventilation ris White, beige tee
tho or
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Vacuum ss Green ac
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un
pt
Test Conditions:
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• The Leak Detection Pump - V144- detected a leak.
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ility
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• Guided Fault Finding was performed using the Vehicle Diag‐
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nostic Tester .
h re
ole,
spec
Evaporative Emissions Tester - KLI9210- Preparation:
t to the co
Note
rrectne
Depending on the version, the appearance of the Evaporative
Emissions Tester - KLI9210- may vary.
ss o
cial p
f in
– Check on the Evaporative Emissions Tester - KLI9210- wheth‐
form
mer
er there is enough fluid in the smoke generator.
atio
m

o
n
c
i
or
n thi
e
– Open the nitrogen bottle -H-.

t
sd
iva
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pr
c
– Connect the measuring hose -G- to the self-test connection
um
r
fo
en
ng
-B-.
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– Using the pressure reducer -J-, adjust the pressure to 10 in.
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cted agen
H2O (25 mbar) on. Prote AG.

– The pressure must now be maintained a minimum of 2 mi‐
nutes. If the pressure is not maintained, check the tester.
Fuel System, Checking for Leaks:
– Connect the Evaporative Emissions Tester - Adapter 55-1 -

KLI9210/55-1- to the vent line -A-. (color identification: white)

– Connect the measuring hose -G- from the Evaporative Emis‐

sions Tester - KLI9210- to the Evaporative Emissions Tester
- Adapter 55-1 - KLI9210/55-1- .

– Start the engine and let it run at idle speed.
for leaks”.
– Start the test.
– Watch the pressure gauge on the Evaporative Emissions
Tester - KLI9210- during the test.
• The Leak Detection Pump - V144- must pump the fuel system
up to minimum 7 in. Inflate H2O (18 mbar).
The minimum pressure is not reached, but the pressure reached
does not decrease:
– Switch ignition off and perform pressure retention test. Refer
to ⇒ page 410 . If no drop in pressure is detected: Check the
vacuum supply from the Leak Detection Pump - V144- . Refer
to agen
AG. Volkswagen AG d
oes
⇒ “13.7.4 Leak VolDetection
ksw Pump V144 , Checkingnot
gu
Vacuum
Supply”, page
sed by 413 . ara
n
ri tee
ho
The minimum
au
t pressure is not reached and the pressure oreached
ra
c
decreases
ss immediately:
ce
le
un
pt
an
d
itte
– Clamp off the hose to the EVAP Canister Purge Regulator

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rm
ab
Valve 1 - N80- with a hose clamp -arrow-.

pe
ility
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– Repeat the test. If the minimum pressure is now reached: Re‐

wit
, is n
h re
place the EVAP Canister Purge Regulator Valve 1 - N80- .

hole
spec
If the minimum pressure is not reached again and the pressure

es, in part or in w
that is reached decreases immediately:

t to the co
– Leak in fuel system: perform “leak test in fuel system”. Refer

to ⇒ “13.7.2 Fuel System Leak Detection”, page 411 .
rrectness of i
If the Minimum Pressure Is Reached, Switch Ignition Off.

l purpos
The valve in the Leak Detection Pump - V144- is now closed and
the pressure is maintained.
nform
ercia
– Observe the pressure gauge:

m
a
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If the pressure does not decrease, perform a pressure retention

n in
r
test to locate any possible pinhole leaks. Refer to ⇒ page 410 .

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If the pressure decreased, clamp off hose to EVAP Canister

Purge Regulator Valve 1 - N80- with a hose clamp -arrow-.
Refer to ⇒ “13.7.2 Fuel System Leak Detection”, page 411 .
Pressure Retention Test
– Set valve -D- to “Test”. Increase the current pressure until it

reaches 10 in. H2O (25 mbar).
Note
Depending on the level in the fuel tank, this procedure may take
up to three minutes.

(20 mbar).
If the Pressure Is Not Maintained for Five Minutes, the Leak
Should Be Localized as Follows:
– First check the EVAP Canister Purge Regulator Valve 1 - N80-

for leaks. To do this, clamp off thelkshose n AG. Volkswagen AG do
wage to the EVAP Canister es n
Purge Regulator Valve 1 - N80-
d by V with a hose clamp -arrow-.
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Prote AG.
– Repeat pressure test by resetting the valve -D- to “Test”.

– Observe the pressure gauge and flow meter. The fuel system
is filled if the flow quantity decreases and the pressure increa‐
ses to 10 in. H2O (25 mbar).
Refer to ⇒ “13.7.2 Fuel System Leak Detection”, page 411 .
Tester .
13.7.2 FuelolkSystem
gen AG Leak Detection
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Test Conditions:
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“Fuel System, Checking for Leaks” is rper‐
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formed. Refer to
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un

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• The Evaporative Emissions Tester - KLI9210- must be con‐

erm
ab
nected to the vehicle with the Adapter Hose - KLI9210/55-1- .

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– Connect the Evaporative Emissions Tester - KLI9210- to the

h re
ole,
vehicle battery.
spec
– Remove the right rear wheel housing liner.

t to the co
– Clamp off the hose between the Leak Detection Pump - V144-
and air filter -arrow-.
rrectne
Eos
ss o
cial p
f inform
mer
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Golf

(20 mbar).
– If the pressure no longer decreases, replace the Leak Detec‐
tion Pump - V144- .
If the Pressure Is Not Maintained for a Minimum of Five Minutes
or If No Pressure Is Built up, Localize the Leak as Follows:
– Fill the fuel system with smoke by setting valve -D- to “Test”.
– While fuel system is being filled, press smoke generator button
-I- for approximately one minute.
The fuel system is now under pressure and filled with smoke.
– Check all fuel system lines and hoses for escaping smoke.
Also check the fuel filler cap.
wage
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Note utho eo
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♦ Illuminate components and hoses with a strong flood light, the

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smoke will be more visible.

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♦ To check for leaks at accessible locations, also use ultrasonic

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measuring device or commercially available leak detection

wit
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spray.
h re
hole
♦ Depending on how long fault finding lasts, the smoke gener‐

spec
es, in part or in w
ator button may need to be pressed again. This ensures there

t to the co
is enough smoke present in the fuel system.

♦ To check fuel pump and fuel filter flange, the assembly open‐
ings in the vehicle interior must be opened.
rrectness of i
l purpos
– Replace the leaking hoses or components.

nf
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rm
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Tester .
atio
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or c
13.7.3 EVAP System, Function Overview

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1 - EVAP Canister
2 - Adapter Hose -
KLI9210/55-1- Component Lo‐
cation
❑ During the leak test in
fuel system
4 - Vent Line
❑ Throttle Valve Control
Module - J338-
5 - Solenoid Valve
Pump - V144-
6 - Vacuum Line
7 - Air Filter n AG. Volkswagen AG do
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❑ For the Leak Detection d byV ua
ran
Pump - V144- ir se tee
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8 - Leak Detection Pump - ss
V144-
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9 - Fuel Tank
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10 - Cap
ility
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13.7.4 Leak Detection Pump - V144- , Check‐

orm
m
ing Vacuum Supply

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Note
♦ Leak Detection Pump - V144- component location

♦ Golf: In the right rear wheel housing under the wheel housing
liner.
♦ Eos: behind the right rear wheel.
Golf:
– Remove the right rear wheel the and wheel housing liner.

V144-
Eos:
V144- wage
es ks not
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All Vehicles:
wit
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hole
– Switch on the measuring range I (absolute pressure meas‐
spec
urement).
es, in part or in w
t to the co
– Connect the Vehicle Diagnostic Tester and start the engine.
rrectness of i
l purpos
for leaks”.
– Start the test.
nform
ercia
– During the test, pay attention to the display on the Turbo‐

m
at
charger Tester Kit - VAG1397A- .
om
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c
in t
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• The pressure must pulsate and must not rise above 0.700 bar
o
his
te
(10.15 psi) (absolute pressure) during the test.

a
do
priv
cum
or
– If the pressure rises above 0.700 bar (10.15 psi) during the
f
en
g
test, the vacuum supply is too low. Check vacuum line to the
n
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intake manifold for kinks or blockages. C py
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14 Special Tools

equipment required
♦ Elbow Assembly Tool -
T10118-
♦ Wrench - Fuel Sending Unit
- T10202-
40-200Nm - VAG1332- n AG. Volkswagen AG do
lkswage es n
♦ Fuel Extraction - Adapter d byV
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ua
Set - VAS5190- o
ir se
ran
tee
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ility
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spec
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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or
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ate
do
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cum
for
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♦ Pressure Tester Kit -

VAS6550-
♦ Injection Rate Comparison
Meter Kit - Remote Cable -
VAG1348/3A-
♦ Vehicle Diagnostic Tester -
Test Adapter - 5 Pin -
VAS5565-
♦ Analog/Digital Multimeter -
FLU83III-
♦ Wrench - Fuel Sending Unit
- T10202-
40-200Nm - VAG1332-
AG. Volkswagen AG d
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♦ Accelerator Pedal Module Release Tool - T10238-

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t to the co
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c
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ate
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♦ Fuel Extraction - Adapter Set - VAS5190-
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CC 2010 ➤ , Eos 2006 ➤AG,. VGolf
olksw2004
agen A➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
agen G do
4-Cylinder FuelVoInjection
lksw Engine (1.8L and es2.0L
not Engine, Chain Drive) - Edition 07.2015
y gu
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♦ Wrench - Fuel thoSending
r
Unit - 3087- eo
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s
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ility
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es, in part or in w
t to the co
rrectness of i
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♦ Hose Clamps - Up To 25mm - 3094-
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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♦ Evaporative Emissions Tester - KLI9210DLX-
♦ Evaporative Emissions Tester - Adapter 55 - KLI9210/55-
♦ Turbo E-Positioner Service Kit - Wire Set - VAS 5051/66-
♦ Pressure Tester Kit - Adapter Set - Fitting - VAS6550/3-1-

21 – Turbocharger, Supercharger
1 Turbocharger
⇒ “1.1 Overview - Turbocharger”, page 419 .
⇒ “1.3 Turbocharger, Removing and Installing”, page 427 .
⇒ “1.4 Turbocharger Vacuum Diaphragm, Checking”,
page 433 .
⇒ “1.6 Turbocharger Vacuum Diaphragm, Removing and Instal‐
ling”, page 438 .
1.1 Overview - Turbocharger

⇒ “1.1.3 Part I ”, page 422
⇒ “1.1.4 Part II”, page 423
⇒ “1.1.5 Part III”, page 424
⇒ “1.1.6 Part IV”, page 425
⇒ “1.1.7 Turbocharger Recirculation Valve N249 Installation Po‐
sition”, page 426
Note
AG. Volkswagen AG d
♦ Secure all hose connections using hose clamps
lkswappropriate
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♦ Hose connections and charge air system utho hoses must be free eo
ra
of oil and grease before installing.ss aOnly on connector cou‐ c
plings, the gasket and sealing surfaces must be lightly oiled.
ce
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nl
pt
Refer to
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♦ The charge air system must be properly sealed.

wit
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hole
♦ Replace the self-locking nuts.

spec
es, in part or in w
♦ Hose Clip Pliers - VAS6362- or the Hose Clip Pliers -

t to the co
VAG1921- are recommended for installing spring clamps.

♦ Fill the turbocharger with engine oil at the connection for oil
rrectness of i
supply line.
l purpos
♦ After installing turbocharger, let engine idle for approximately

1 minute without increasing engine speed. This ensures ade‐
quate oil supply to the turbocharger.
nf
ercia
orm

m
atio
m

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or c
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1. Turbocharger 419
Part I - Engine codes BZB,

CGYA, CDAA and CDAB. Re‐
fer to
⇒ “1.1.2 Part I, Engine Codes
BZB, CGYA, CDAA and
CDAB”, page 421 .
Part l - Engine Codes CAWB,
CBFA, CCTA, CCTB, CCZA,
CCZB, CCZC, and CCZD. Re‐
fer to
⇒ “1.1.3 Part I ”, page 422 .
Part II - Refer to
⇒ “1.1.4 Part II”, page 423
Part III - Refer to
⇒ “1.1.5 Part III”, page 424
Part IV - Refer to
⇒ “1.1.6 Part IV”, page 425
AG. Volkswagen AG d
agen oes
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ab
ility
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wit
is n
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
i
or
n thi
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420 Rep. Gr.21 - Turbocharger, Supercharger

1.1.2 Part I, Engine Codes BZB, CGYA, CDAA and CDAB
1 - Turbocharger agen
AG. Volkswagen AG d
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❑ Can onlyd bbe y V replaced
o gu
ara
with exhaust
orise manifold nte
and autvacuum diaphragm.
h eo
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❑ Removing
s
and instal‐
ce
le
ling. Refer to
un
pt
an
d
⇒ “1.3 Turbocharger,
itte
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rm
ab
pe
ility
ling”, page 427 .
ot
wit
, is n
h re
hole
spec
3 - Turbocharger Vacuum Dia‐
es, in part or in w
phragm
t to the co
⇒ “1.4 Turbocharger
rrectness of i
Vacuum Diaphragm,
l purpos

ling. Refer to
nform
ercia
Vacuum Diaphragm,
m
a
com
tio
ling”, page 438 . n in
r
te o
thi
❑ Adjusting. Refer to
s
iva
do
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rp
cum
Vacuum Diaphragm,
fo
en
g
Adjusting, Engine Co‐

n
t.
yi Co
op
des BZB, CGYA, CDAA C py
t. rig
and CDAB”, page 434 .
gh ht
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4 - Seal Prote
cted AG.
agen
❑ Always replace
5 - Ring Connection
6 - Banjo Bolt
❑ 8 Nm
7 - Hose
8 - Hose
9 - Bolt
❑ 3 Nm
10 - Wastegate Bypass Regulator Valve - N75-
11 - Hose
12 - Seal
13 - Connection
14 - Clip
15 - Bolt
❑ 9 Nm
16 - Bolt
❑ 7 Nm
17 - Turbocharger Recirculation Valve - N249-
❑ Note the installation position. Refer to
⇒ “1.1.7 Turbocharger Recirculation Valve N249 Installation Position”, page 426 .
1. Turbocharger 421
18 - Seal
1.1.3 Part I
1 - Turbocharger
❑ Can only be replaced
with exhaust manifold
and vacuum diaphragm.
ling. Refer to
ling”, page 427 .
phragm
Vacuum Diaphragm,
ling. Refer to
Vacuum Diaphragm,
ling”, page 438 . AG. Volkswagen AG d
agen oes
lksw not
4 - Hose d by Vo gu
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5 - Hose utho eo
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6 - Bolt s
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❑ 3 Nm
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erm
7 - Wastegate Bypass Regula‐

ab
ility
tor Valve - N75-

ot p
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8 - Hose
h re
hole
spec
9 - Connection
es, in part or in w
t to the co
10 - Clip
11 - Bolt
rrectness of i
❑ 9 Nm
l purpos
12 - Seal
13 - Turbocharger Recirculation Valve - N249-
nform
ercia
❑ Note the installation position. Refer to

m
at
⇒ “1.1.7 Turbocharger Recirculation Valve N249 Installation Position”, page 426 .

om
ion
c
in t
14 - Bolt
or
his
ate
❑ 7 Nm
do
priv
cum
or
15 - Seal
f
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Cop py
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Prote AG.

lkswage es n
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d ran
ir se
CC 2010 th ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤
o tee
or , Passat 2006 ➤ , ...
u
4-Cylinder FuelsInjection
s a
Engine (1.8L and 2.0L Engine, Chain Drive) ac
- Edition 07.2015
ce
e
nl
pt
du
1.1.4 Part II
an
itte
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erm
ab
ility
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wit
1 - Seal
, is n
h re
❑ Always replace
hole
spec
es, in part or in w
2 - Banjo Bolt
t to the co
❑ 33 Nm
3 - Oil Supply Line
rrectness of i
4 - Turbocharger
l purpos

nf
ercia
orm
m
atio
m
ling. Refer to
o
n in
c
or
thi
e

t
sd
iva
ling”, page 427 .
o
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rp
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f
en
ng
5 - Bolt yi
t.
Co
op
❑ 9 Nm
C py
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6 - Bolt cop Vo
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❑ 9 Nm Prote AG.
7 - Seal
❑ Always replace
8 - Banjo Bolt
❑ 38 Nm
9 - Bolt
❑ 9 Nm
10 - Banjo Bolt
❑ 38 Nm
❑ For removing and instal‐
ling, the turbocharger
must be removed
11 - Seal
❑ Always replace
12 - Coolant Supply Line
❑ For removing and installing, the turbocharger must be removed
13 - O-Ring
❑ Always replace
14 - Bolt
❑ 9 Nm
15 - Seal
❑ Always replace
16 - Oil Return Line
17 - Bolt
❑ 9 Nm
18 - Seal
❑ Always replace
1. Turbocharger 423
1.1.5 Part III
1 - Seal
❑ Always replace
AG. Volkswagen AG d
2 - Nut ksw
agen oes
not
Vol
❑ Tightening sequence. ed by gu
ara
Refer to horis nte
eo
⇒ Fig. ““Turbocharger - s aut ra
c
Tightening Sequence”“ , s
ce
e
page 425
nl
pt
du
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itte
❑ Always replace
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ab
❑ Coat exhaust manifold
ility
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stud bolts with hot bolt
wit
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paste. Hot bolt paste:
h re
hole
Refer to Parts Catalog.
spec
es, in part or in w
3 - Banjo Bolt
t to the co
❑ 38 Nm
rrectness of i
must be removed
l purpos
4 - Seal
nf
ercia
❑ Always replace
orm
m
5 - Coolant Supply Line
atio
om
n in
or c
thi
te
sd
a
must be removed
iv
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m
6 - Bolt
f
en
ng
t.
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❑ 9 Nm Cop py
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7 - Turbocharger p by
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by c lksw
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agen
Prote AG.
ling. Refer to
Removing and Installing”, page 427 .
8 - Bracket
9 - Bolt
❑ 30 Nm
❑ Coat the bolt with hot bolt paste. Hot bolt paste: Refer to Parts Catalog.
10 - Bolt
❑ 30 Nm
❑ Coat the bolt with hot bolt paste. Hot bolt paste: Refer to Parts Catalog.
11 - Nut
❑ 30 Nm
❑ Always replace
❑ Do not loosen to remove the turbocharger
❑ Coat exhaust manifold stud bolts with hot bolt paste. Hot bolt paste: Refer to Parts Catalog.
12 - Frame

Turbocharger - Tightening Sequence

– Tighten the bolts -1 through 5- in four steps as follows:
1.1.6 Part IV
Note
Only engine codes BZB, CGYA, CDAA and CDAB have an ad‐
justable vacuum diaphragm.
1 - Turbocharger
with exhaust manifold AG. Volkswagen AG d
and vacuum diaphragm. agen oes
olksw not
V gu
❑ Removing and instal‐ d by ara
ise nte
ling. Refer to thor eo
⇒ “1.3 Turbocharger, s au ra
c
s
Removing and Instal‐ ce
le
ling”, page 427 .

un
pt
an
d
itte
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rm
ab
phragm
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ility
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wit
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h re
hole
spec
Vacuum Diaphragm,
es, in part or in w

t to the co

ling. Refer to
rrectness of i
Vacuum Diaphragm,
l purpos

ling”, page 438 .
❑ Adjusting - engine co‐
nform
ercia
des BZB, CGYA, CDAA

m
and CDAB only. Refer to

a
com
tio
n in
r
Vacuum Diaphragm,
te o
thi
Adjusting, Engine Co‐

s
iva
do
r
des BZB, CGYA, CDAA

rp
cum
fo
and CDAB”, page 434 .

en
ng
t.
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op
3 - Bolt C py
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❑ 10 Nm pyri by
Vo
co lksw
by
cted agen
4 - Nut Prote AG.
❑ 9 Nm
❑ Engine codes BZB,
CGYA, CDAA and
CDAB only
❑ Secure with sealing wax
1. Turbocharger 425
5 - Locking Plate
❑ Engine codes BZB, CGYA, CDAA and CDAB only
6 - Knurled Nut
❑ Engine codes BZB, CGYA, CDAA and CDAB only
1.1.7 Turbocharger Recirculation Valve -

N249- Installation Position
– Note the installation location -arrows-.
1.2 Hose Connections with Connector Cou‐

plings, Assembling
Caution
The connector coupling sealing ring can be damaged if secur‐

ing clamp is in locked position when installing. This would result
in a leak. Follow the assembly instructions. agen
AG. Volkswagen AG d
oes
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V gu
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Removing: ut
ho eo
ra
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– Release the connector coupling by pulling locking clip s
ce
le
-arrow-. Disconnect the hose/tube without assistance from

un
pt
an
d
tools.
itte
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Installing ab
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– Oil the sealing surfaces and the gasket.

– Bring the securing clip into the release position -1-.
rrectne
– Slide the charge air hose into clutch until it stops.

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Removing:
page 465 .
Golf, Eos:
All:
– Remove the front section of the right wheel housing liner or
the front right wheel housing liner. Refer to ⇒ Body Exterior;
1. Turbocharger 427
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .
– Remove the engine cover.
– Disconnect the connectors from the ignition coils and the wir‐
ing harness and lay them aside.

-arrow-.
– Disconnect the vacuum line -1- at the separating point -2- and
free up the wire.
– Remove the coolant hoses -arrows- from the coolant pipe.
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inder head.
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– Seal the turbocharger with the Engine Bung Set - VAS6122- .

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On 2.0L engines, remove the bolt -2- from the heat shield using
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1. Turbocharger 429

– Remove the bolts -1- and remove the turbocharger support.
Vehicles with FWD:
– Remove the right drive axle heat shield -arrows-.

All:
Tiguan. Refer to

-arrows-.
AWD Vehicles:
– Tie up the driveshaft to the left in thewatunnel.
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Steering; Rep. Gr. 40 ; Drive
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– Remove the bolt -1- using the Socket - Xzn 10 - T10154- .

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1. Turbocharger 431
– Remove the turbocharger/exhaust manifold upward.

Installing:
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♦ Assembly of hose connections with connection couplings. Re‐
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♦ Secure all hose connections using hose clamps appropriate
for the model type.

4-Cylinder Fuel Injection Engine (1.8L and e2.0L Engine, Chain Drive) - Edition 07.2015
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⇒ “1.1 Overview - Turbocharger”, page 419 hor.is eo
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Exhaust manifold/turbocharger to the cylinder Note the tight‐
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Tightening
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page 425 .
Oil supply line to turbocharger (M12 banjo bolt) 33
rrectne
Oil return line to the turbocharger 9
Coolant supply line to the turbocharger (tighten 38
ss
M14 banjo bolt with Bits for V.A.G. 1331/13 -
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T10099- )
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Turbocharger bracket to cylinder block 2) 30
atio
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Turbocharger bracket to turbocharger 2) 30
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1.4 Turbocharger Vacuum Diaphragm,

Checking
Test Conditions:
♦ The hose from the turbocharger over Wastegate Bypass Reg‐
ulator Valve - N75- must have flow to the vacuum diaphragm.
♦ Wastegate Bypass Regulator Valve - N75- OK
Procedure:
– Connect the Hand Vacuum Pump - VAS6213- to the vacuum
diaphragm -arrow-.
1. Turbocharger 433
– Set the slide ring -1- on Hand Vacuum Pump - VAS6213- to

position -B- for “vacuum”.
Caution
The pressure must not exceed 750 mbar. If the pressure is

exceeded, the vacuum diaphragm can be damaged.
– Operate the Hand Vacuum Pump - VAS6213- several times

and observe the linkage.
The linkage -A- must move approximately 300 mbar (4.35 psi)
and be at approximately 700 mbar (10.15 psi) at the end position.
The linkage stroke is approximately 10 mm.
Note
If pressure cannot be raised using the Hand Vacuum Pump -

VAS6213- or pressure drops immediately, check the Hand Vac‐
uum Pump - VAS6213- and connecting hoses for leaks. If no fault
is detected: replace the vacuum diaphragm. Refer to
⇒ “1.6 Turbocharger Vacuum Diaphragm, Removing and Instal‐
ling”, page 438 . olkswage es n
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1.5 Turbocharger Vacuum Diaphragm, Ad‐ ss
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♦ Pressure Control Valve - VAS6342-

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Note
♦ Some vehicles are equipped with vacuum diaphragms which

are not adjustable.
♦ The vacuum diaphragm must be adjusted only if the linkage
was loosened.
♦ The adjustment is performed only with the turbocharger re‐
moved.
– Disconnect the hose -arrow- from the vacuum diaphragm at

turbocharger.
– Loosen the clip above linkage on the turbocharger.
– Loosen the lock nut -2-.
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1. Turbocharger 435
– Connect the Hand Vacuum Pump - VAS6213- and the Turbo‐

charger Tester Kit - VAG1397A- to connection II and the Seal
Installer - Crankshaft - VAS6342- as shown in the illustration.
– Close the Pressure Control Valve - VAS6342- at the lever
-1-.
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– Set the slide ring -1- on Hand Vacuum Pump - VAS6213-
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– Secure the Dial Gauge Holder - VW387- on the turbocharger

-arrow-.
– Secure the Dial Gauge Set - Dial Gauge - VAS6341/1- with
the Dial Gauge Set - Extension - 30mm - VAS6341/3- and Dial
Gauge Set - Flat Pickup - VAS6341/4- to the Dial Gauge Hold‐
er - VW387- .
– Set the Dial Gauge Set - Dial Gauge - VAS6341/1- at 0 bar to
1 mm pre-load.
– Turn the display on the Dial Gauge Set - Dial Gauge -
VAS6341/1- to 0.
– Check dial indicator for ease of movement.
– Operate the Hand Vacuum Pump - VAS6213- until the Turbo‐
charger Tester Kit - VAG1397A- displays 460 +/- 5 mbar.
– The dial gauge must display 4.1 mm to 4.3 mm. If it does not,
rotate the vacuum diaphragm linkage until the value is dis‐
played. AG. Volkswagen n AG do
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– Tighten the lock nut yby
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– Set the Dial Gauge Set - Dial Gauge - VAS6341/1- to 0.

rrectness of i
Note
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The following measurements must be performed in one se‐

quence. In the meantime, the pressure must not dissipate to 0.
nform
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charger Tester Kit - VAG1397A- displays 460 +/- 5 mbar.

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charger Tester Kit - VAG1397A- displays 650 mbar to 700 C py
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VAS6342- to 460 +/- 5 mbar.
– Read and note the value on the Dial Gauge Set - Dial Gauge
- VAS6341/1- .
– Add value 1 and 2 together and divide by two.
– The result (mean value) must be 5 ± 0.25 mm.
– If the result (mean value) is not 5 ± 0.25 mm, correct the ad‐
justment, tighten the lock nut hand-tight and repeat the meas‐
urement.
– If the result (mean value) is 5 ± -0.25 mm, tighten the lock nut
to 9 Nm and secure with sealing wax.
1. Turbocharger 437
– Secure the locking plate -1- over vacuum diaphragm linkage.
1.6 Turbocharger Vacuum Diaphragm, Re‐

Removing:
– Remove the turbocharger. Refer to
– Remove the circlip form the vacuum diaphragm linkage
– Remove the vacuum diaphragm -1- from the turbocharger

-arrows-.
Installing:
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Install in reverse order of removal
Vol
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Component ss Nm
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Vacuum diaphragm to turbocharger 10

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Rep. Gr.21 - Turbocharger, Supercharger
2 Charge Air System

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⇒ “2.1 Overview - Charge
ksw Air Cooling System, Passat,
age G do
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and Eos”, paged439y Vol. ot g
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⇒ “2.2 Overview
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ho - Charge Air Cooling System, Golf”, page
e o 440 .
r
a ac
ss
⇒ “2.3 Overview - Noise Generator, Golf”, page 442 .
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an
⇒ “2.4 Structure-Borne Sound Actuator R214 and Structure
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Borne Sound Control Module J869 ”, page 443 .
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⇒ “2.5 Overview - Turbocharging System”, page 446 .
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⇒ “2.6 Charge Air Cooler, Removing and Installing, Golf and Eos”,
ole,
spec
page 446 .
t to the co
⇒ “2.7 Charge Air Cooler, Removing and Installing, Passat, and
CC”, page 448 .
⇒ “2.8 Charge Air Cooler, Removing and Installing, Tiguan”, page
rrectne
449 .
s
⇒ “2.9 Charge Air Guide to Noise Generator, Removing and In‐
s o
stalling Rabbit”, page 450 .
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⇒ “2.10 Charge Air System, Checking for Leaks”, page 451 .
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2.1 Overview - Charge Air Cooling System,

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The charge air pipe clamps must be tightened to 5.5 Nm. An
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insufficient or excessive tightening torque can cause the
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charge air hose to come off the charge air pipe while driving.
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2. Charge Air System 439

1 - Bolt
❑ 5 Nm
2 - Bearing
❑ For the charge air cooler
3 - Charge Air Cooler agen
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⇒ “2.7 Charge Air Cool‐ ss c
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⇒ “2.8 Charge Air Cool‐
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stalling, Tiguan”,
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page 449 .
4 - Charge Air Pipe
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5 - Bolt
❑ 10 Nm
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mer
7 - Charge Air Hose
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❑ Refer to the installation

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instructions. Refer to
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⇒ “1.2 Hose Connec‐

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va
tions with Connector

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Couplings, Assem‐
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bling”, page 426

t.
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8 - To the Throttle Valve Con‐
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9 - Charge Air Hose
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10 - Bolt
❑ 10 Nm
11 - Bolt
❑ 5 Nm
12 - Charge Air Pressure Sensor - G31-
13 - Charge Air Pipe
14 - Charge Air Hose
❑ Refer to the installation instructions. Refer to
⇒ “1.2 Hose Connections with Connector Couplings, Assembling”, page 426
2.2 Overview - Charge Air Cooling System,

Golf
Caution
The charge air pipe clamps must be tightened to 5.5 Nm. An

insufficient or excessive tightening torque can cause the
charge air hose to come off the charge air pipe while driving.

Note
The sound generator is not installed on all vehicles.
1 - Bolt
❑ 5 Nm
2 - Bearing
❑ For the charge air cooler
3 - Charge Air Cooler
ling. Refer to
⇒ “2.7 Charge Air Cool‐
stalling, Passat, and
CC”, page 448 .
4 - Charge Air Pipe
5 - Bolt swage
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❑ 10 Nm d byV ua
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6 - Charge Air Hose utho
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❑ Assembly of hose con‐ ss
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7 - Charge Air Pipe

t to the co
❑ to the sound generator

ling. Refer to
rrectne
⇒ “2.9 Charge Air Guide

to Noise Generator, Re‐
s

s o
Rabbit”, page 450 .

cial p
f inform
8 - Charge Air Hose

mer
atio
m

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c
ling. Refer to
i
or
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⇒ “2.9 Charge Air Guide to Noise Generator, Removing and Installing Rabbit”, page 450 .
te
sd
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❑ Assembly of hose connections with connection couplings. Refer to

i
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⇒ “1.2 Hose Connections with Connector Couplings, Assembling”, page 426 .

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9 - Hose Clamp Cop py
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❑ Overview. Refer to ⇒ “2.3 Overview - Noise Generator, Golf”, page 442 .
14 - Bolt
❑ 8 Nm

15 - Sound Generator
❑ Assembly of hose connections with connection couplings. Refer to
⇒ “1.2 Hose Connections with Connector Couplings, Assembling”, page 426 .
19 - Bolt
❑ 5 Nm
2.3 Overview - Noise Generator, Golf
Note
The sound generator is not installed on all vehicles. From

04/2009, the sound generator is being replaced by the Structure-
Borne Sound Actuator - R214- .
1 - Cover
2 - Bolt
❑ 8 Nm
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9 - Spacer Sleeve
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10 - Rubber Bushing
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11 - Sound Generator
❑ Before removal, remove
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⇒ Item 1 (page 442)
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head; Overview - Bulkhead .
rrectness of i
Overview - Structure-Borne Sound Actuator - R214- and Struc‐
l purpos
ture-Borne Sound Control Module - J869- . Refer to

⇒ “2.4.2 Overview - Structure-Borne Sound Actuator R214 and
nform
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Structure-Borne Sound Control Module J869 ”, page 443 .

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2.4.2 Overview - Structure-Borne Sound Actuator - R214- and Structure-Borne
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1 - Structure Borne Sound

Control Module - J869-
❑ Component location: in‐
side the plenum cham‐
ber
❑ Remove the plenum
chamber cover and ple‐
num chamber bulkhead
to remove and install.
2 - Bolt
❑ 8 Nm
3 - Nut
❑ 8 Nm
4 - Structure-Borne Sound Ac‐
tuator - R214- Bracket
5 - Nut
❑ 15 Nm
6 - Bolt
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2.4.3 Overview - Structure-Borne Sound Actuator - R214- and Structure-Borne

Sound Control Module - J869- , RHD

Control Module - J869- Brack‐
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Control Valve - N316-
8 - Vacuum Diaphragm for the
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15 - Check Valve
16 - Charge Air Pressure Reg‐
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17 - Wastegate Bypass Regu‐
lator Valve - N75-
18 - Turbocharger Recircula‐
tion Valve - N249-
19 - Turbocharger
2.6 Charge Air Cooler, Removing and In‐

stalling, Golf and Eos
Removing:
– Remove the bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63 .


The condenser pipes are bolted to the right side of the charge air
cooler. To remove the bolt, proceed as follows:
– Create a paper template with the specified dimensions.
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The condenser bolts are difficult to access. With the help of a
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second technician, lift the charge air cooler out of the lower radi‐ hole
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ator mounts. Now the charge air cooler can be pivoted »back and
es, in part or in w
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– Remove the condenser from the charge air cooler -arrows-.
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– Secure the condenser to the lock carrier with cable ties.
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– Remove the charge air cooler downward.
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Installing:
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stalling, Passat, and CC
Removing:
Gr. 63 .
– Remove the air guides from the lock carrier. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Lock Carrier ;Overview - Lock Carrier .

– Remove the charge air cooler bracket bolts -1-.
Note
The condenser bolts are difficult to access. With the help of a

second technician, lift the charge air cooler out of the lower radi‐
ator mounts. Now the charge air cooler can be pivoted »back and
forth« and the bolts are accessible. swa
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stalling, Tiguan
Gr. 63 .
– Unclip the left and right air guides from the lock carrier. Refer
to ⇒ Body Exterior; Rep. Gr. 50 ; Lock Carrier ;Overview -
Lock Carrier .

– Remove the charge air cooler bracket bolts -arrows-.

– Attach the condenser and the cable tie to the lock carrier.
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2.9 Charge Air Guide to Noise Generator,
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the air duct.

duct.

– Open the latch -1-, unclip the fuel lines -2- and loosen the bolts
-3-.
– Loosen the clamp -arrow- and remove the charge air guide.
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2.10 Charge Air System, Checking for Leaks

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♦ Turbo System Tester Kit - VAG1687-
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– Connect Turbo System Tester Kit - Adapter 5 - VAG1687/5-

to the charge air hose -A- and rotate it around approximately
90° -B-.
Prepare the Turbo System Tester Kit - VAG1687- as follows:

– Turn the pressure regulating valve -2- counterclockwise until

it stops.
– Close the valves -3 and 4-.
Note
In order to be able to turn pressure regulator valve -2-, the rotary

knob must be pulled upward.
– Connect the Turbo System Tester Kit - VAG1687- as shown:
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– Connect the pressure hose -1- (pressurized air supply) to the
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Turbo System Tester Kit - VAG1687- .
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If water is located in viewing glass, drain it via the water drain plug
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– Open the valve -3-.
rrectness of i
– Set pressure to 0.5 bar (7.2 psi) using the pressure regulator
valve -2-.
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Caution
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The pressure must not exceed 0.5 bar (7.2 psi)! A pressure set
com
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too high may damage the engine.
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the Ultrasonic Tester - VAG1842S- .
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Note
♦ Assembly of hose connections with connection couplings. Re‐

fer to
♦ A small quantity of air dissipates via the valves in the engine.
For this reason a pressure retention test is not possible.
♦ Information on the Ultrasonic Tester - VAG1842S- . Refer to
the Operating Instructions.
♦ Before removing the adapter, discharge the pressure in testing
circuit by pulling off the coupling from the Turbo System Tester
Kit - Adapter 5 - VAG1687/5- .
of oil and grease before installing.

3 Special Tools n AG . Volkswagen AG

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♦ Pressure Control Valve -
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VAS 6342-
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♦ Turbocharger Tester Kit -
VAG1397A-
rrectness of i
♦ Dial Gauge Set - VAS6341-
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♦ Torque Wrench 1783 -

2-10Nm - VAG1783-
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4-Cylinder Fuel Injection Engine (1.8L andAG2.0L
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♦ Hose Clip Pliers - ed ran
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♦ Turbo System Tester Kit - VAG1687-

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♦ Turbo System Tester Kit - Adapter 5 - VAG1687/5-

24 – Multiport Fuel Injection

1 Safety Precautions and Clean Work‐
ing Conditions
⇒ “1.1 OBD General Information”, page 457
1.1 OBD General Information

OBD, General Information. Refer to
⇒ “1.1 OBD General Information”, page 457 .
Safety Precautions. Refer to
♦ The engine control module is equipped with OBD. Before re‐ AG. Volkswagen AG d
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♦ Fuel hoses in the engine compartment mayss only be secured c
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♦ For the electric components to work properly, a voltage of at
ility
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♦ Do not use sealants containing silicone. Particles of silicone
hole
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components that are drawn into the engine are not burned
es, in part or in w
there, and they damage the heated oxygen sensors.
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♦ The vehicles have an emergency fuel shut-off. It reduces the
risk of fire in a collision because the fuel pump relay switches
rrectness of i
the fuel pump off.
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♦ At the same time this setup also makes it easier to start the
engine. When the driver-side door is opened, the fuel pump is
activated for two seconds so that pressure builds in the fuel
nform
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system. Observe the safety precautions. Refer to

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1. Safety Precautions and Clean Working Conditions 457

2 Injection System
⇒ “2.1 Technical Data”, page 458 .
⇒ “2.2 Overview - Component Locations”, page 458 .
⇒ “2.3 Overview - Air Filter”, page 463 .
⇒ “2.4 Air Filter Housing, Removing and Installing”, page 465 .
⇒ “2.5 Air Filter Element, Removing and Installing”, page 465 .
⇒ “2.6 Mass Airflow Sensor G70 , Removing and Installing”, page
466 .
⇒ “2.7 Overview - Intake Manifold”, page 467 .
⇒ “2.8 Overview - Fuel Rail”, page 470 .
⇒ “2.9 Intake Manifold with Fuel Rail”, page 471 .
⇒ “2.10 Fuel Injectors, Removing and Installing”, page 478 .
⇒ “2.11 Fuel Injector Teflon® Seal, Always replace”, page 481 .
⇒ “2.12 Fuel Injectors, Cleaning”, page 482 .
⇒ “2.13 Fuel Pressure Sensor G247 , Removing and Installing”,
page 483 .
⇒ “2.14 Throttle Valve Control Module J338 , Removing and In‐
⇒ “2.15 Throttle Valve Control Module J338 , Cleaning”,
page 486 . AG. Volkswagen AG d
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⇒ “2.16 Overview - High Pressure Pump with Fuel Pressured by V Reg‐
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ara
ulator Valve N276 ”, page 486 . orise nte
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⇒ “2.17 High Pressure Pump, Removing and Installing”,
ss a c
page 487 .
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2.1 Technical Data
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Engine Codes CBFA and CCTA

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Idle speed 1) RPM 640 to 800
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Engine speed limitation RPM approximately 6500

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1)If the engine control module voltage supply drops below 12

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volts, the idle speed is increased in stages up to 990 RPM. Idle

speed is not adjustable.
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2.2 Overview - Component Locations

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Components A through E are not shown in the exploded view

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458 Rep. Gr.24 - Multiport Fuel Injection

1 - Camshaft Adjustment Valve

1 - N205-
ling. Refer to
⇒ “1.2 Camshaft Adjust‐
ment Valve 1 N205 , Re‐
page 91 .
2 - Wastegate Bypass Regula‐
tor Valve - N75-
❑ Installed directly on the
turbocharger. Refer to
⇒ Fig. ““Components on
the Turbocharger”“ ,
page 463
3 - Turbocharger Recirculation
Valve - N249-
❑ Installed directly on the
turbocharger. Refer to
⇒ Fig. ““Components on
the Turbocharger”“ ,
page 463
4 - Ignition Coils with Power
Output Stages
ling. Refer to
⇒ “1.4 Ignition Coils with
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❑ Ignition Coil 1 with Pow‐ autho
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❑ Ignition Coil 2 with Pow‐

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❑ Ignition Coil 3 with Pow‐ ility
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❑ Ignition Coil 4 with Power Output Stage - N292-

h re
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❑ The ignition coils must be pulled out of the cylinder head using the Puller - Ignition Coil - T40039-
es, in part or in w
t to the co
5 - Engine Control Module - J623-

❑ Removing and Installing, Passat and CC. Refer to
⇒ “4 Engine Control Module J623 , Passat and CC through 11/2010”, page 495 .
rrectness of i
❑ Removing and Installing, Rabbit and Eos. Refer to

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⇒ “5 Engine Control Module J623 , Golf and Eos through 11/2008”, page 499 .
❑ Removing and installing, Tiguan. Refer to ⇒ “7 Engine Control Module J623 , Tiguan”, page 507 .
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❑ Removing and installing, Scirocco. Refer to

⇒ “8 Engine Control Module J623 , Scirocco through 11/2008”, page 511 .
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6 - High Pressure Pump with Fuel Pressure Regulator Valve - N276-

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❑ Component Location:
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Refer to ⇒ Fig. ““High Pressure Pump, Engine Codes”“ , page 461

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❑ Removing and installing. Refer to ⇒ “2.17 High Pressure Pump, Removing and Installing”, page 487 .
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❑ Overview. Refer to
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7 - Fuel Pressure Regulator Valve - N276-
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❑ Component Location:
Refer to ⇒ Fig. ““High Pressure Pump, Engine Codes”“ , page 461
2. Injection System 459

8 - Engine Coolant Temperature Sensor on Radiator Outlet - G83-

❑ Passat, CC, Golf, Eos and Scirocco: inside the lower radiator connection. Refer to
⇒ “3.1 Overview - Radiator, Fan Shroud and Radiator Fan, Passat, CC, Golf, and Eos”, page 260 .
❑ Tiguan: inside the coolant hose. Refer to
⇒ “3.3 Overview - Radiator, Fan Shroud and Radiator Fan, Tiguan”, page 262 .
9 - Vacuum Diaphragm for the Charge Motion Valve
❑ Component location. Refer to ⇒ Fig. ““ Intake Manifold Runner Control Valve -N316- -2- ”“ , page 461 .
10 - Intake Manifold Runner Control Valve - N316-
❑ Component location. Refer to ⇒ Fig. ““ Intake Manifold Runner Control Valve -N316- -2- ”“ , page 461 .
11 - Engine Speed Sensor - G28-
❑ Left lower front installation location. Refer to ⇒ Fig. ““ Engine Speed Sensor -G28- -1- ”“ , page 462
❑ Component location. Refer to ⇒ Fig. ““ Charge Air Pressure Sensor -G31- -1- ”“ , page 463 .
13 - Knock Sensor 1 - G61- Connector
❑ Installed location beneath intake manifold. Refer to ⇒ Fig. ““Connectors”“ , page 462
❑ Knock Sensor 1 - G61- tightening specification: 20 Nm
14 - Camshaft Position Sensor - G40- Connector
15 - 8-Pin Connector for Fuel Injectors
16 - Throttle Valve Control Module - J338-
❑ With EPC Throttle Drive - G186- , EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive
Angle Sensor 2 - G188-
❑ After replacing the Throttle Valve . VControl
olkswagenModule - J338- , it must be adapted to the Engine Control
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Module - J623- . ReferlkstowaVehicle Tester
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17 - EVAP Canister Purge
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❑ With checkauvalve/restrictor
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❑ To remove and install, remove the intake manifold
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18 - Intake Air Temperature Sensor - G42-

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❑ Bolted to the intake manifold at the front. Refer to ⇒ “2.7 Overview - Intake Manifold”, page 467 .
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19 - Knock Sensor 1 - G61-

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❑ 20 Nm
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❑ On the front cylinder block under the intake manifold

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20 - Engine Coolant Temperature Sensor - G62-

❑ Inside the coolant pump housing. Refer to
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⇒ Fig. ““ Engine Coolant Temperature Sensor -G62- -1- ”“ , page 463

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21 - Camshaft Position Sensor - G40-

❑ Bolted on the front cylinder head cover. Refer to
⇒ Fig. ““ Camshaft Position Sensor -G40- -1- ”“ , page 462
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22 - Fuel Pressure Sensor - G247-

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❑ On the fuel rail. Refer to ⇒ “2.8 Overview - Fuel Rail”, page 470 .
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23 - Intake Manifold Runner Position Sensor - G336-

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❑ On the right intake manifold

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❑ To remove and install, remove the intake manifold. Refer to

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24 - Oil Pressure Switch - F1- p by
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❑ Inside the auxiliary components bracket
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Refer to ⇒ “3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure Switch F1 ”, page 217 .

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A - Diagnostic Connector
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❑ In the driver side footwell
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B - Mass Airflow Sensor - G70- and Intake Air Temperature Sensor 2 - G299-
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❑ Component location. Refer to
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⇒ Fig. ““ Mass Airflow Sensor -G70- and Intake Air Temperature Sensor 2 -G299- -1- ”“ , page 462 .
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⇒ “2.6 Mass Airflow Sensor G70 , Removing and Installing”, page 466 .
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C - Accelerator Pedal Position Sensor - G79- and Accelerator Pedal Position Sensor 2 - G185-
❑ On accelerator pedal (both sensors are stored in one housing)
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❑ If the accelerator pedal module or engine control module is replaced in vehicles with automatic trans‐
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missions, the kick down function must be adapted.

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⇒ “10.2 Accelerator Pedal Module, Removing and Installing”, page 381 .

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D - Radiator Fan Control Module - J293-
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❑ The Radiator Fan Control Module - J293- is integrated in the Radiator Fan - V7- .
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E - Fuel Injectors
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❑ In the fuel rail
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❑ Removing and installing. Refer to ⇒ “2.10 Fuel Injectors, Removing and Installing”, page 478 .
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❑ Cylinder 1 Fuel Injector - N30- opyri
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❑ Cylinder 2 Fuel Injector - N31-

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High Pressure Pump, Engine Codes

2 - High Pressure Fuel Pump
Intake Manifold Runner Control Valve - N316- -2-


Mass Airflow Sensor - G70- and Intake Air Temperature Sensor

2 - G299- -1-
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Engine Speed Sensor - G28- -1- yV
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Camshaft Position Sensor - G40- -1-
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1 - From Camshaft Position Sensor - G40-
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2 - From Knock Sensor 1 - G61-

3 - 8-Pin Connector for Fuel Injectors

Engine Coolant Temperature Sensor - G62- -1-
Note
Under the intake manifold (the intake manifold is not shown in the
illustration).
Charge Air Pressure Sensor - G31- -1-
Components on the Turbocharger

1 - Turbocharger, Removing and Installing. Refer to
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2 - Tighten the Wastegate Bypass Regulator Valve - N75- Vol to 3
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3 - Tighten the Turbocharger Recirculation Valveau - N249- to 7 Nm ac
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(observe installation location, next illustration)
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Observe the Installed Location of the Turbocharger Recirculation

Valve - N249-
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2.3 Overview - Air Filter

1 - Spring Clamp
2 - Air Duct Hose
❑ To the turbocharger
❑ Check the air guide
hose for dirt and leaves
3 - Mass Airflow Sensor - G70-
ling. Refer to
⇒ “2.6 Mass Airflow
Sensor G70 , Removing
and Installing”,
page 466 .
4 - Bolts
❑ 1.5 Nm
❑ For the air filter housing
upper section
5 - Bolts
❑ 1.5 Nm
❑ For the air filter housing
upper section
6 - Air Filter Upper Section
❑ Clean salt, dirt and
leaves from the upper
section of the air filter.
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❑ Removing and instal‐ ss
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❑ Note the replacement
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8 - Bolt
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❑ 8 Nm
❑ For the air filter lower section
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9 - Snow Screen
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❑ Not installed on all vehicles

10 - Air Filter Lower Section
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❑ Clean the lower section of the air filter from salt, dirt and leaves.
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11 - Water Drain Hose Connection

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❑ Clean the connection

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12 - Water Drain Hose

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❑ To lock carrier
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❑ Clean dirt and leaves from the intake air guide

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2.4 Air Filter Housing, Removing and Instal‐
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Engine Code CBFA
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– Disconnect the hose leading to the Secondary Air Injection
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Pump Motor - V101- from the air filter housing.
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– Disconnect the connector -1- from the Mass Airflow Sensor -

G70- .
– Open the hose clamps -2 and 3- and remove the connecting
pipe.
– Remove the bolt -4- and pull the air filter housing upward out
of the fastener.
Installing:
2.5 Air Filter Element, Removing and Instal‐

ling
Removing
Engine code CBFA:
– Disconnect the hose leading to the Secondary Air Injection
Pump Motor - V101- from the air filter housing.
All:
– Remove the bolts -arrows- from the air filter upper section.

– Lift the air filter upper section and remove the air filter element.
Installing
⇒ “2.3 Overview - Air Filter”, page 463 .
Note
♦ Always use an original air filter element.

of oil and grease before installing. When installing, do not use
any lubricants containing silicone.
♦ The air filter housing must be clean.
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♦ Observe the disposal regulations!
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– Check the mass airflow sensor and intake hose (intake air
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– Check the air intake hose from the air duct for debris.
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– Remove the snow screen -1- and clean it.
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The snow screen is not installed in all vehicles.
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– Clean the water drain -arrow- and the air filter lower section.
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– Set the air filter upper section carefully onto the air filter lower
section, without using much force. When doing this, make sure
that the upper section of air filter housing is not placed crooked
onto the air filter element. Check the sealing lip on the air filter
element.
2.6 Mass Airflow Sensor - G70- , Removing

and Installing
– Disconnect the connector -1- from the Mass Airflow Sensor -
G70- .

– Remove both bolts from the Mass Airflow Sensor - G70- and
carefully remove the Mass Airflow Sensor - G70- from the air
filter housing guide. wage
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♦ If the air filter is very dirty or soaked, dirt particles or moisture
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may have contaminated the Mass Airflow Sensor - G70- and
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may be causing false mass airflow values. This results in a
spec
reduction of power, since a lower injection quantity is calcula‐
es, in part or in w
t to the co
ted.
♦ Always use an original air filter element.
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♦ Use a lubricant (silicone-free) for installing the intake hose.
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– Check the mass airflow sensor and intake hose (intake air
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and lower section of salt residue, dirt and leaves. Wash or
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Install in reverse order of removal. Prote AG.
2.7 Overview - Intake Manifold

1 - Bolt for Intake Air Temper‐

ature Sensor - G42-
❑ 5 Nm
2 - Intake Air Temperature
Sensor - G42-
❑ With check valve/re‐
strictor as one unit
❑ To remove and install,
remove the intake mani‐
fold
4 - Intake Manifold
ling. Refer to
⇒ “2.9 Intake Manifold
with Fuel Rail”,
page 471 .
❑ Bolt tightening specifi‐
cation -item 15-
⇒ Item 15 (page 471) .
5 - Vacuum Diaphragm for the
Charge Motion Valve
6 - High Pressure Pump Bolts
❑ Always replace
❑ M6 thread = 8 Nm + 90°
❑ M8 thread = 20 Nm
7 - Connection for the Fuel
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8 - Fuel Pressure ed Regulator
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❑ The fuel system must be without pressure to install the high-pressure pump. Releasing the fuel pressure.
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❑ Install the fuel line to the fuel rail free from tension
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❑ Overview - High Pressure Pump. Refer to

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10 - Roller Tappet
❑ Remains inserted in cylinder head after removing the high-pressure pump, removable
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11 - High Pressure Fuel Line Connection

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❑ Tightening specification. Refer to

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12 - Fuel Line to the Fuel Rail

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❑ 18 Nm
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❑ Do not install fuel line with tension

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13 - Intake Manifold Runner Control Valve - N316-

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14 - Fuel Injectors
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❑ Make sure it is installed in the correct position.
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❑ Removing and installing. Refer to ⇒ “2.10 Fuel Injectors, Removing and Installing”, page 478 .
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15 - Check Valve/Restrictor
❑ Allocations for different versions. Refer to Parts Catalog.
❑ With EVAP Canister Purge Regulator Valve 1 - N80- , one unit
16 - Intake Manifold Support
17 - Bolt for the Intake Manifold Support
❑ 23 Nm
18 - Nut for the Intake Manifold
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19 - Bolts for uthe
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20 - Throttle Valve Control Module - J338- , EPC Throttle Drive - G186-
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❑ EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive Angle Sensor 2 - G188-
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❑ After replacing the Throttle Valve Control Module - J338- , it must be adapted to the Engine Control
h re
hole
Module - J623- . Refer to Vehicle Diagnostic Tester “Guided Functions”.
spec
es, in part or in w
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⇒ “2.14 Throttle Valve Control Module J338 , Removing and Installing”, page 484 .
❑ Cleaning. Refer to ⇒ “2.15 Throttle Valve Control Module J338 , Cleaning”, page 486 .
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21 - Seal
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❑ Always replace
❑ The rim of the gasket must fit into the groove provided for it inside the intake manifold.
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2.8 Overview - Fuel Rail
1 - Fuel Injector
❑ With combustion cham‐
ber seal (Teflon® seal),
always replace
❑ Replace the O-rings
❑ Make sure it is installed
in the correct position.
ling. Refer to
⇒ “2.10 Fuel Injectors,
ling”, page 478 .
2 - Support Ring
3 - Fuel Rail
ling. Refer to
⇒ “2.9.2 Fuel Rail, Sep‐
arating from Intake
Manifold”, page 477 . agen
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not enter the fuel system
when installing the high
pressure pump.
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❑ The fuel system must be
without pressure to in‐
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stall the high-pressure pump. Releasing the fuel pressure. Refer to

⇒ “1 Safety Precautions”, page 272 . nf
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❑ Install the fuel lines free of tension

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❑ Removing and installing. Refer to ⇒ “2.17 High Pressure Pump, Removing and Installing”, page 487 .
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❑ Overview - High Pressure Pump. Refer to

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5 - Roller Tappet
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❑ M6 thread = 8 Nm + 90°
8 - Fuel Supply Line Connections
❑ 22 Nm
❑ Always replace
9 - Fuel Supply Line Union Nut
❑ 18 Nm

10 - Charge Motion Valves

11 - Seal
❑ Always replace
❑ Removing and installing. Refer to ⇒ “2.9 Intake Manifold with Fuel Rail”, page 471 .
❑ Checking. Refer to ⇒ “3.2 Variable Intake Manifold, Checking”, page 492 .
14 - Throttle Valve Control Module - J338- , EPC Throttle Drive - G186-
❑ EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive Angle Sensor 2 - G188-
❑ After replacing the Throttle Valve Control Module - J338- , it must be adapted to the Engine Control
Module - J623- . Refer to Vehicle Diagnostic Tester “Guided Functions”.
15 - Intake Manifold Bolts
❑ Tighten to 3 Nm, and then tighten to 9 Nm
16 - Intake Manifold Runner Position Sensor - G336-
❑ To remove and install, remove the intake manifold. Refer to
⇒ “2.9 Intake Manifold with Fuel Rail”, page 471
17 - Fuel Pressure Sensor - G247-
❑ 27 Nm
❑ Coat the threads with clean engine oil.
❑ Checking. Refer to ⇒ “3.1 Fuel Pressure Sensor G247 , Checking”, page 490 .
⇒ “2.13 Fuel Pressure. Sensor
VolkswageG247 , Removing and Installing”, page 483 .
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Additional
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tightening specifications can be found at the end
of
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⇒ “2.9.2 Fuel Rail, Separating from Intake Manifold”, page 477 .

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2.9 Intake Manifold with Fuel Rail

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⇒ “2.9.1 Intake Manifold with Fuel Rail, Removing and Installing”,

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page 471
spec
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⇒ “2.9.2 Fuel Rail, Separating from Intake Manifold”, page 477

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2.9.1 Intake Manifold with Fuel Rail, Remov‐

ing and Installing
rrectness of i
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If the intake manifold is replaced, the Intake Manifold Runner Po‐

sition Sensor - G336- must be adapted to the Engine Control
Module - J623- using a Vehicle Diagnostic Tester .
nform
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♦ Torx Socket - T30 - T10347-

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♦ Wrench - Oil Filter - 3417-

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Note
♦ Follow all Safety Precautions. Refer to

♦ To access the fuel injectors, the intake manifold and the fuel
rail with air control charge motion valve must be removed.
♦ The combustion chamber seal (Teflon®) and the O-ring must
always be replaced. AG. Volkswagen AG d
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♦ Overview - Intake Manifold. Refer by Vto
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⇒ “2.7 Overview - Intake Manifold”,
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Overview - Fuel Rail. Refer
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air guide for the sound generator. Refer to
h re
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es, in part or in w
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rrectness of i
– Clean the contact surface from the intake manifold to the cyl‐
inder head.
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page 465 .
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– Disconnect the following connectors:
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♦ Intake Air Temperature Sensor - G42- -1-
♦ Throttle Valve Control Module - J338- -2-
♦ EVAP Canister Purge Regulator Valve 1 - N80-
♦ Camshaft Position Sensor - G40-

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4-Cylinder Fuel Injection Engine (1.8L
aut and 2.0L Engine, Chain Drive) - Edition 07.2015 ra
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– Disconnect the vacuum line -1- at the separating point -2- and
pt
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remove the crankcase ventilation hose -3-.
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WARNING
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Fuel system is under pressure.
spec
es, in part or in w
Risk of injury from fuel spraying out.
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♦ Wear safety gloves.
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♦ Reduce the pressure: Lay clean cloths around the con‐
nection point and carefully open the connection point.
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– Remove the bolts -arrows- for the fuel supply line and lay the
o
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line to the side.

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– Open the fuel line union nut -lower arrow-.
– Disconnect the vacuum line -arrow- from the Intake Manifold

Runner Control Valve - N316- .

– Remove the bolts -arrows- for the coolant line from the intake
manifold.
– Disconnect the connector -1- from the Fuel Pressure Sensor

- G247- .
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– Remove the charge air hose -A- and then cover the charge air
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– Remove the bracket from the intake manifold -arrows-.
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– Remove the Throttle Valve Control Module - J338- -arrows-.
spec
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– Remove the intake manifold support by removing the mount‐

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– Remove the oil filter. Refer to Cop py
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Switch F1 ”, page 217 . cop Vo
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– Loosen the wiring bracket -arrows-.
– Loosen the wire -arrow- from the intake manifold.
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– Remove the nuts -A- and loosen the bolts -arrows- from the
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intake manifold using the Torx Socket - T30 - T10347- .
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– Carefully pull the intake manifold and fuel rail away from the
ab
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cylinder head just a little.
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– Disconnect the connector -arrow- from the Intake Manifold
h re
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Runner Position Sensor - G336- and remove the intake mani‐
spec
fold.
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– Cover the intake channels with a clean cloth.
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Note
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The fuel injectors could remain stuck in the fuel rail. nform
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– Disconnect the fuel rail from the intake manifold. Refer to

⇒ “2.9.2 Fuel Rail, Separating from Intake Manifold”,
page 477 .
Installing:
• Fuel injector must be installed in the cylinder head. Install the
fuel injectors. Refer to
– Mount the intake manifold onto the cylinder head on the stud
bolts (lower left and right).
Note
Make sure the fuel injectors are installed correctly and pay atten‐
tion to the wiring bracket when mounting the intake manifold
(under the intake manifold).
• When installing the intake manifold, the manifold must be

pulled out slightly and the fuel injectors will stick in the fuel rail.
Pull the fuel injectors out of the fuel rail and insert them in the
cylinder head again.
cedures. Note the following:
– When attaching the wiring bracket onto the intake manifold,

make sure it clips into both retainers.
Tightening Specifications. Refer to AG. Volkswagen AG d
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⇒ “2.7 Overview - Intake Manifold”,
Volksw page 467 . oes
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Tightening specifications.
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⇒ “2.8 Overview -aFuel
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2.9.2 Fuel Rail, Separating from Intake Mani‐

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Note
s
The intake manifold must be removed. Refer to

s o
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⇒ “2.9 Intake Manifold with Fuel Rail”, page 471 ; Intake Manifold,
in
Removing
form
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– Remove the EVAP Canister Purge Regulator Valve 1 - N80-

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in direction of -arrow- from the bracket.

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– Loosen both bolts -arrows- from the fuel rail. t. C rig
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– Remove the fuel rail from the intake manifold.

Installing
– Tighten the fuel line.
– Install in reverse order of removal.
– Reconnect the connector.
– Install the intake manifold. Refer to
Adapter for the fuel line to the fuel rail 25 Nm
Fuel line (union nut) to fuel rail adapter 18 Nm
2.10 Fuel Injectors, Removing and Installing

♦ Injector/Combustion Chamber Seal Tool Set - T10133B-
Note
AG. Volkswagen AG d
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Modify the Puller - T10133/2- to Create the Puller - T10133/2A- .

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♦ Round file approximately 6mm

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– File the semicircle as shown in the illustration. The semi-circle

ole,
spec
allows the tool to slide farther onto the fuel injector, thus pro‐
viding the tool with a larger contact surface.

t to the co
– Mark the modified tool with an “A” at the end of the tool num‐
ber.
rrectness o
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Fuel Injector, Old Version

1 - Combustion Chamber Seal (Teflon® Seal) - replace; the seal
must not be greased or be treated with any other lubricant during
installation.
2 - The support ring is being replaced by an intermediate ring. See
fuel injector (new version).
3 - Fuel Injector
4 - Spacer Ring (replace ifAGdamaged)
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6 - Support
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Fuel Injector, New Version
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1 - Intermediate ring, replace
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2 - Mount
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3 - Combustion Chamber Seal (Teflon® Seal) - replace; the seal
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must not be greased or be treated with any other lubricant during
installation.
4 - Fuel Injector
5 - Spacer Ring (replace if damaged) rrectness of i
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6 - O-ring (replace, coat lightly with clean engine oil when instal‐
ling)
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7 - Support ring (via this support ring, the fuel rail utilizes the force
m
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to hold the fuel injector in place in the cylinder head).

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Removing:
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– Remove the intake manifold with the fuel rail. Refer to

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Remove the injector valves if they remain attached in the fuel rail.
– Cover the intake channels with a clean cloth.
– Remove the support element -A- downward and disconnect

the connector -arrows- from the fuel injectors.

– Position the Puller - T10133/2A- in the groove on the fuel in‐

jector.
– Mount the Injector/Combustion Chamber
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♦ Pay attention to the intermediate rings.
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♦ The Teflon® seal must always be replaced before installing the
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fuel injector. Refer to
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⇒ “2.11 Fuel Injector Teflon® Seal, Always replace”,
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page 481 .
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Installing:
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Note
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♦ The fuel injector Teflon® seal may not be oiled or greased.

♦ It is possible that an opened intake valve hinders the cleaning.
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In this case, engine must be turned farther by hand using a
rm
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screw wrench on the crankshaft.
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– Thoroughly clean the holes for the high pressure fuel injectors
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in the cylinder head using the Injector/Combustion Chamber
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Seal Tool Set - Brush - T10133/4- .

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– Replace the Teflon® seal on the fuel injector. Refer to . C rig
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⇒ “2.11 Fuel Injector Teflon® Seal, Always replace”, py by
co Vo
page 481 .
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– Assemble the fuel injector with the parts from the repair kit.
– Press the fuel injector by hand into cylinder head (free of oil
and grease) until they stop. Make sure the fuel injectors are
positioned correctly -arrow- inside the cylinder head.

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Note tho
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If it is difficult to install the fuel injector by hand, use the Injector/
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Combustion Chamber Seal Tool Set - Puller - T10133/2A- -2- with
du
an
itte
the Injector/Combustion Chamber Seal Tool Set - Sliding Ham‐
y li
erm
ab
mer - T10133/3- to guide in the fuel injector.
ility
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– Install the support ring onto the fuel injector.
h re
hole
spec
– Lightly coat O-rings for the high pressure fuel injector with
es, in part or in w
clean engine oil before installing
t to the co
– Install the intake manifold with the fuel rail. Refer to
rrectness of i
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2.11 Fuel Injector Teflon® Seal, Always re‐

place
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The Teflon® seal must not be oiled. Cop py
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– Carefully remove the old Teflon® seal with the appropriate tool
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(for example cut the seal open with a razor blade, spread it
AG.
outward with a small screwdriver and remove it forward).

When doing this, be sure not to damage the groove and the
surrounding rib in the groove base.
– Thoroughly clean the fuel injector in the area of the sealing
ring -arrow-. Remove any deposits (coking) using a brass
brush.
– Clean the gasket groove.
– Insert a new sealing ring onto the Injector/Combustion Cham‐

ber Seal Tool Set - Assembly Cone - T10133/5- . Slide the seal
as far as possible onto the Injector/Combustion Chamber Seal
Tool Set - Assembly Cone - T10133/5- using the Injector/
Combustion Chamber Seal Tool Set - Assembly Sleeve -
T10133/6- .

– Rotate the Injector/Combustion Chamber Seal Tool Set - As‐

sembly Sleeve - T10133/6- and slide the seal up to the end of
the Injector/Combustion Chamber Seal Tool Set - Assembly
Cone - T10133/5- .
– Set the Injector/Combustion Chamber Seal Tool Set - Assem‐

bly Cone - T10133/5- onto the fuel injector and slide the seal
onto the fuel injector using the Injector/Combustion Chamber
Seal Tool Set - Assembly Sleeve - T10133/6- .
olksw
– Remove the Injector/Combustion Chamber agen Seal Tool SetA-G does
AG. V agen
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Assembly Cone - T10133/5- and bslide
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with the Injector/Combustion rChamber
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sembly Sleeve - T10133/6-uth.
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ility
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– Press the Injector/Combustion Chamber Seal Tool Set - Cal‐
h re
ole,
ibration Sleeve - T10133/7- all the way onto the fuel injector
spec
using a gentle turning motion (approximately 180°).
t to the co
– Pull off the Injector/Combustion Chamber Seal Tool Set - Cal‐
ibration Sleeve - T10133/7- again using turning motion in
opposite direction.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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e
– Now press the Injector/Combustion Chamber Seal Tool Set -

t
sd
va
Calibration Sleeve - T10133/8- all the way onto the fuel injector
i
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cum
using a gentle turning motion (approximately 180°).

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t.
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– Pull off the Injector/Combustion Chamber Seal Tool Set - Cal‐ Cop py
ibration Sleeve - T10133/8- again using turning motion in ht. rig
rig ht
opposite direction.
py by
co Vo
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– Replace the O-ring and support washer on fuel injector.
Prote AG.
2.12 Fuel Injectors, Cleaning

♦ Ultrasonic Cleaning Unit - VAS6418-
♦ Ultrasonic Cleaning Unit - Mounting Plate for Injection Mod‐
ules - VAS6418/1-
♦ Ultrasonic Cleaning Unit - Cleaning Fluid - VAS6418/2-

Cleaning
– Remove the fuel injectors. Refer to
Note
Follow the safety precautions and the instructions for the ultra‐
sonic device.
– The ultrasonic device must be filled with Ultrasonic Cleaning

Unit - Cleaning Fluid - VAS6418/2- .
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Note d byV ua
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Fill the ultrasonic device up to the upperssedge
au of the holes with ac
cleaner (see the magnified area of the illustration).
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du
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itte
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– Insert the fuel injectors -1- all the way into the Mounting Plate
erm
ab
for Injection Modules - VAS6418/1- -2-.
ility
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spec
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t to the co
– Dip the fuel injectors with the Mounting Plate for Injection
Modules - VAS6418/1- into the cleaner.
rrectness of i
– Adjust the temperature to 50 degrees using the knob -4-.
l purpos
– Set a cleaning time of 30 minutes using the knob -5-.
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– Switch the ultrasonic device on with the button -3-.
orm
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Note
or
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The time begins counting down once the cleaning temperature o

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reaches 50 degrees.
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Cop py
.
– Replace the combustion chamber seal (Teflon® seal) after
t rig
gh ht
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cleaning each fuel injector. Refer to cop Vo
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⇒ “2.11 Fuel Injector Teflon® Seal, Always replace”,
cted agen
Prote AG.
page 481 .
– Install the fuel injectors. Refer to
2.13 Fuel Pressure Sensor - G247- , Remov‐

ing and Installing
♦ Double Hexagon Socket - 27mm - VAS5301/7-
Removing:
Refer to

All:
– Remove the upper bracket from the Generator - C- -arrow-.
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– Loosen the coolant pipe -arrows- from the intake manifold.
spec
es, in part or in w
t to the co
WARNING
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– Disconnect the connector from the Fuel Pressure Sensor -
o
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f
en
ng
G247- using the Elbow Assembly Tool - T10118- .

t.
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Cop py
– Remove the Fuel Pressure Sensor - G247- using the Double
t. rig
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Hexagon Socket - 27mm - VAS5301/7- .
p by
co Vo
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– Collect escaping fuel with a cleaning cloth.
Installing:
Coat the Fuel Pressure Sensor - G247- sealing point with clean
engine oil.
– Tightening specifications. Refer to
2.14 Throttle Valve Control Module - J338- ,

Removing:
Refer to


All:
– Remove the air guide pipe -1 and 2-.
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– Remove the bolt -1- and remove
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– Disconnect the connector
isedb -1- at the Throttle Valve Controluaran
Module - J338- . thor tee
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spec
es, in part or in w
t to the co
– Remove the bolts -arrows- and the Throttle Valve Control

Module - J338- .
rrectness of i
Installing:
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orm
⇒ “2.7 Overview - Intake Manifold”, page 467 .

m
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– Clean the sealing surface on the O-ring.

or c
thi
te
– Replace the seal; when doing so, make sure the position in‐
sd
iva
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dicator on the gasket is in the correct position.

rp
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ng
– If a new Throttle Valve Control Module - J338- was installed,

t.
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adapt the engine control module to the Throttle Valve Control C py
ht. rig
Module - J338- . Refer to Vehicle Diagnostic Tester in “Guided rig ht
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Functions”.
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2.15 Throttle Valve Control Module - J338- ,

Cleaning
♦ Acetone
Note
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♦ Follow all the guidelines
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⇒ “2 Guidelines
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ara
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♦ The throttle
sa
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ra
c
cleaning.
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Procedure:
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– Remove the throttle valve control module. Refer to
ot p
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⇒ “2.14 Throttle Valve Control Module J338 , Removing and
, is n
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hole
spec
– Open throttle valve by hand and hold it in open position with a
es, in part or in w
t to the co
suitable object -arrow-.
WARNING
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Acetone is easily flammable. Observe accident prevention

measures and the safety precautions when working with easily
flammable fluids. Do not used compressed air when cleaning
nf
ercia
throttle valve. Always wear protective eyewear and protective

orm
clothing to prevent injuries and contact with skin.

m
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om
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– Clean throttle valve connections, especially in area of closed

sd
iva
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throttle valve, with standard acetone and a brush.

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– Wipe throttle valve connections with a lint-free cloth.

t.
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Cop py
t.
– Allow acetone to dry completely and reinstall cleaned throttle
rig
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valve control module. cop Vo
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Prote AG.
– Adapt new engine control module to the throttle valve control
module. Refer to Vehicle Diagnostic Tester “Guided func‐
tions”.
2.16 Overview - High Pressure Pump with

Fuel Pressure Regulator Valve - N276-
Note
Note the different versions of the connection for the fuel high
pressure line.

1 - O-Ring
❑ Always replace
2 - Roller Tappet
❑ Remains inserted in cyl‐
inder head after remov‐
ing the high-pressure
pump, removable
High Pressure Line (with Inner
Threads)
❑ 40 Nm
❑ Always replace
❑ Counterhold the con‐
nection when loosening
the union nuts
High Pressure Line (with Outer
Threads)
❑ 25 Nm
❑ Always replace
❑ Counterhold the con‐
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the union nuts
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❑ With Fuel Pressure Regulator Valve - N276-

❑ Make sure that dirt does not enter the fuel system when installing the high pressure pump.
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❑ Install the fuel line to the fuel rail free from tension
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2.17 High Pressure Pump, Removing and In‐

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♦ Catch escaping fuel with a cleaning cloth.
♦ Always replace the O-ring and the connection.
♦ Always install the high pressure fuel lines so that they are free
of tension.

Removing
tor Valve - N276- .
WARNING

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– Open both fuel lines -arrows-.
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– Carefully pull the high pressure fuel pump out. The roller tap‐
pet may stay in the cylinder head.
Installing
Note
♦ To insert the high pressure pump, the roller tappet must be at

its lowest point.
♦ If the same or a used high pressure pump is installed, replace
the fuel supply line connections (high pressure side). Over‐
view - High Pressure Pump. Refer to
⇒ “2.16 Overview - High Pressure Pump with Fuel Pressure
Regulator Valve N276
swa
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G. Volk486 .
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♦ Tightening ris specifications. Refer to
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– Replace the O-ring for the high-pressure pump.
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– Install the high pressure pump into the vacuum pump.

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– Tighten the bolts by hand.
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– Replace the connections on the high pressure pump.

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– Tighten the bolts diagonally with the required torque.

– Tighten the fuel supply line union nut by hand, »align it so there
nf
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is no tension« and then tighten it.

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– Connect the connector -2- for the Fuel Pressure Regulator

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Valve - N276- again.

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3.1 Fuel Pressure Sensor - G247- , Check‐
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♦ Double Hexagon Socket - 27mm - VAS5301/7-
ss
♦ Pressure Sensor Tester - VAS6394/1-
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♦ Pressure Sensor Tester - Adapter 2 - VAS6394/2-
form
mer
♦ Pressure Sensor Tester - Adapter 4 - VAS6394/4- (Tiguan on‐
atio
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ly)
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♦ Vehicles with sound generator: Engine Bung Set - VAS6122-
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Procedure:
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– Remove the Fuel Pressure Sensor - G247- . Refer to
⇒ “2.13 Fuel Pressure Sensor G247 , Removing and Instal‐
ling”, page 483 .
– Seal the charge air guide connection to the sound generator
with a plug from the Engine Bung Set - VAS6122- and secure
it with a hose clamp.
Note
For the Tiguan, use the Pressure Sensor Tester - Adapter 4 -

VAS6394/4- instead of the Pressure Sensor Tester - Adapter 2 -
VAS6394/2- .
– Coat the sealing point on the Pressure Sensor Tester - Adapt‐

er 2 - VAS6394/2- with clean engine oil and install in the fuel
rail. Tightening specification: 27 Nm.

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,. VGolf
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– Remove the sealing plug -2- and install the hFuel
rise Pressure nte
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Sensor - G247- in the Fuel Pressure Sensor
s au - VAS6394/1- . ra
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Tightening specification: 27 Nm. s
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– Connect the pressure line for the Pressure Sensor Tester
an
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Adapter - VAS6394/1- to the Pressure Sensor Tester - Adapter
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2 - VAS6394/2- .
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– Connect the Fuel Pressure Sensor - G247- and the Fuel Pres‐
sure Sensor - VAS6394/1- connector using the Vehicle Diag‐
ss
nostic Tester - Test Adapter - 3 Pin - VAS5570- .
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cial p
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3. Components, Checking 491

– Switch the Pressure Sensor Tester Adapter - VAS6394/1- on

by pressing the button -A- briefly.
Note
♦ Holding the button -A- for 2 seconds switches on the illumina‐

tion for 20 seconds.
♦ If the Pressure Sensor Tester - VAS6394/1- does not display
0 bar, set it back to zero. Refer to the Operating Instructions.
– Connect the Vehicle Diagnostic Tester to the diagnostic con‐

nector.
– Press the following buttons on the Vehicle Diagnostic Tester
screen one after another.
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– Select measured
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Display field 3 shows the fuel pressure actual value as measured
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– Start the engine.

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Tester - VAS6394/1- with the actual value displayed on the

h re
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spec
es, in part or in w
• The pressures may have a maximum difference of 5 bar (72.5

t to the co
psi).
– If the difference is greater than 5 bar (72.5 psi), replace the
rrectness of i
Fuel Pressure Sensor - G247- .

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WARNING
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– Repeat the test with the new Fuel Pressure Sensor - G247-
AG.
and compare both measured values.

If the Measured Values Do Not Match Again:
– Perform a wiring test. Refer to Vehicle Diagnostic Tester .
3.2 Variable Intake Manifold, Checking

Only perform the test if there is a loss of torque. That means there
is reduced elasticity or reduced engine acceleration.


Test Conditions
♦ The Intake Manifold Runner Control Valve - N316- was
checked with the Vehicle Diagnostic Tester .
If the Intake Manifold Runner Control Valve - N316- is OK, per‐
form the following tests:
– Remove the engine cover.
– Start engine and let run at idle.
– Have a second person increase engine speed abruptly (press
accelerator pedal). Observe the intake manifold change-over
vacuum actuator.
• The actuator must activate in direction of -arrow-.
If change-over does not function as specified:
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– Check the vacuum system for leaks. gu
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this by operating the linkage
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– Check that vacuum hoses are not porous.
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Manifold Runner Control Valve - N316- from the Intake Mani‐
fold Runner Control Valve - N316- -2-.
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– Set the slide ring -1- of the Hand Vacuum Pump - VAS6213-
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3. Components, Checking 493

– Connect the Hand Vacuum Pump - VAS6213- to the Intake

Manifold Runner Control Valve - N316- actuator.
The vacuum actuator must move in direction of -arrows-.
– Replace the vacuum actuator if it does not move.
AG. Volkswagen AG d
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4 Engine Control Module - J623- , Pas‐

sat and CC through 11/2010
⇒ “4.1 Engine Control Module, Removing and Installing”,
page 495 .
⇒ “4.2 Engine Control Module with Protective Housing, Removing
4.1 Engine Control Module, Removing and

Installing
Note
Engine Control Module with Protective Housing, removing and

installing. Refer to
AG. Volkswagen
– If the engine control module will be replaced,
wage
n
connect the Ve‐
AG do
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ua
gine Control Module” guided
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Remove Engine Control sModule:
sa c
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erm
ab
Windshield Wiper System; Wiper Arms, Removing and Instal‐
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– Remove the right plenum chamber cover. Refer to ⇒ Body
spec
Exterior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum
Chamber Cover .
t to the co
– Disconnect the connector -1- from the Windshield Defogger
Control Module - J505- .
rrectne
– Slide the connector catches -2- on the engine control module

outward and remove both connectors.
ss o
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– Remove the bolts -3-.

f inform
mer
– Remove the mounting frame with engine control module from

atio
the plenum chamber.

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Installing the Engine Control Module: Prote AG.
4. Engine Control Module J623 , Passat and CC through 11/2010 495

– Slide the engine control module -1- in the direction of -arrow-

into mounting frame.
– Place the mounting frame with the engine control module on

to bracket -4-. Tightening specifications for the bracket mount‐
ing nuts -4-: 6 Nm.
– Tighten the bolts -3- to 7 Nm.
– Connect the connector on the engine control module and slide
the catches -2- toward the inside.
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– Connect the connector by -1- to the Windshield Defogger Control
Vo ot g
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Module - J505- .orised ran
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– Install the right
ra
ss plenum chamber cover. Refer to ⇒ Body Ex‐ c
terior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum Chamber
ce
le
un
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Cover .
an
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– Install the windshield wiper arms. Refer to ⇒ Rep. Gr. 92 ;

erm
ab
ility

ot p
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spec
4.2 Engine Control Module with Protective

t to the co
Housing, Removing and Installing

rrectne
♦ Locking pliers
s
– If the engine control module will be replaced, connect the Ve‐

s o
cial p
hicle Diagnostic Tester and perform the “Always replace En‐

f in
gine Control Module” guided function.

form
mer
atio
Removing:
om
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– Remove the engine control module cover, if equipped.
– Cover the plenum chamber with a clean cloth so that it does
not get scratched.
– Raise the engine control module with frame slightly.

– Release engine control module in direction of -arrows- and pull

it out slightly.
– Bend the raised ends -1- of locking bracket outward.

– Remove the shear bolts -2- with locking pliers and remove the
locking bracket.
– Remove the engine control module.

Installing:
AG. Volkswagen AG d
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– Slide the engine control module -1- in direction of -arrow- into
ce
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the mounting frame until it engages.

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– Tighten the mounting frame.

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Tightening specification: 6 Nm
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4. Engine Control Module J623 , Passat and CC through 11/2010
Prote
cted AG.
agen

the catches -1- inward.
– Take a new locking bracket and tighten new shear bolts evenly
until bolt heads shear off.
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
er .
ling .
AG. Volkswagen AG d
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5 Engine Control Module - J623- , Golf

and Eos through 11/2008
page 499 .

Installing
AG. Volkswagen AG d
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If the engine control module wills be replaced, connect the Vehicle
s c
Diagnostic Tester and perform the “Always replace Engine Con‐
ce
e
nl
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du
trol Module” guided function.
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Removing
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– Remove the windshield wiper arms, plenum chamber cover
es, in part or in w
and plenum chamber bulkhead. Refer to ⇒ Rep. Gr. 92 ;
t to the co
ling .
rrectness of i
– Disconnect the front connector -1- from engine control mod‐
ule.
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– Pry up locking mechanism -2- slightly.
nf
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– Then slide the engine control module out of the retainer
orm
-arrow-.
m
atio
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– Disconnect the rear connector from the engine control module.

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Installing
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– Connect and lock the rear connector to the engine control

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– Connect and lock the front connector to the engine control
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module.
Prote AG.
– Install the plenum chamber bulkhead, the plenum chamber

cover and the wiper arms. Refer to ⇒ Rep. Gr. 92 ; Windshield

♦ Window Cutter - VAG1561A-
♦ Window Cutter - Saw Set - VAG1561/14-
♦ Locking pliers
♦ Hot air gun from Wiring Harness Repair Set - VAS1978B- .
5. Engine Control Module J623 , Golf and Eos through 11/2008 499
Note
If the engine control module will be replaced, connect the Vehicle

Removing:
– Remove the windshield wiper arms, plenum chamber cover
and plenum chamber bulkhead. Refer to ⇒ Rep. Gr. 92 ;
ling .
Note
The threads of the shear bolts are equipped with locking com‐
pound. By heating the shear bolts using a hot air gun, the adhe‐
sive effect of the locking compound is lowered.
Caution
Cover the wires, connectors and control modules nearethe AGen‐

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Perform the adjustments on the hot ut
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– Turn potentiometer for temperature adjustment -2- to maxi‐

un
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mum heat output (600 °C (1,112 °F)).
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– Move the two stage switch for air quantity -3- to position 3.
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es, in part or in w
By heating the shear bolts, parts of the protective housing are

t to the co
heated intensely. Wear protective gloves to prevent injuries.

rrectness of i
– Guide nozzle of hot air gun on to shear bolts.

l purpos
– Switch the heat gun on and warm the bolts.

– Unscrew the bolts using Locking Pliers .
nform
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If the bolts cannot be removed, saw into the heads of the shear
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bolts so two parallel surfaces are formed -arrows- and then re‐
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– Insert a screwdriver -A- between the protective housing andolks
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the retaining plate -arrow-. db
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– Pry the protective housing upward using a screwdriver -A- and
pull it off sideways from retaining plate -arrow-.
rrectness of i
– Disconnect the front connector -1- from engine control mod‐
l purpos
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nform
– Pry up locking mechanism -2- slightly.
mercia
– Then slide the engine control module out of the retainer
a
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-arrow-.
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Installing: cted agen
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– Connect and lock the rear connector to the engine control

module.
– Slide the engine control module onto the retaining plate.
– Connect and lock the front connector to the engine control
module.
– Slide the protective housing on to the retaining plate.
– Tighten the shear bolts -1- uniformly until bolt heads shear off.
– Install the plenum chamber bulkhead, the plenum chamber

cover and the wiper arms. Refer to ⇒ Rep. Gr. 92 ; Windshield
5. Engine Control Module J623 , Golf and Eos through 11/2008 501
6 Engine Control Module - J623- , Golf

and Eos from 11/2008, CC from
11/2010
page 502 .

Installing AG. Volkswagen
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If the engine control module will be replaced,
s
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t to the co
– Remove the windshield wiper arms, the plenum chamber cov‐
er and the plenum chamber bulkhead. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum
rrectne
Chamber Cover .
s
Passat CC:
s o
cial p
f
– Remove the windshield wiper arms and plenum chamber cov‐
inform
er. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Trim Moldings and
mer
Trim; Plenum Chamber Cover .

atio
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All:
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– Push the retaining frame in direction of -arrow- downward and

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remove the engine control module.

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– Push the retainers in the direction of -arrow- and disconnect

the connector.
Installing

– Connect the connector on the engine control module and push

the retainers all the way in direction of -arrow-.
– Mount the engine control module into the retaining frame and
push it in the direction of -arrow- upward.
– Install the windshield wiper arms, the plenum chamber cover
and the plenum chamber bulkhead. Refer to ⇒ Body Exterior;
er . agen
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Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Trim
ss Moldings and
ce
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d
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spec
Note
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♦ If the engine control module will be replaced, connect the Ve‐
hicle Diagnostic Tester and perform the “Always replace En‐
rrectne
gine Control Module” guided function.
♦ The thread on the shear bolts may have locking compound on
ss
them. For easier removal, warm the shear bolts using a Wiring
o
cial p
f
Harness Repair Set - Hot Air Blower - VAS1978/14A- . Do not
inform
to damage any wires, connectors or components nearby when
mer
doing this.
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er and the plenum chamber bulkhead. Refer to ⇒ Body cop Vo
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Exterior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum cted agen
Prote AG.
Chamber Cover .
Passat CC:
– Remove the windshield wiper arms and plenum chamber cov‐
er. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Trim Moldings and
6. Engine Control Module J623 , Golf and Eos from 11/2008, CC from 11/2010 503
All:
– Push the retaining frame in direction of -arrow- downward and
– Remove the shear bolts -arrows- with pliers.

– Slide a screwdriver between both locking plates -arrow-. AG. Volkswagen AG d
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rrectness o
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– Push the retainers in the direction of -arrow- and disconnect

the connector.
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the retainers all the way in direction of -arrow-.
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– Place the locking bracket -1- on the connectors and press it in

hole
spec
the direction of -arrow-.

es, in part or in w
t to the co
– Tighten the bolts -2- in the hole on the engine control module
as far as the stop.
rrectness of i
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– Secure the locking bracket to the engine control module

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-arrows- with new shear bolts.

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-arrows-.
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6. Engine Control Module J623 , Golf and Eos from 11/2008, CC from 11/2010 505
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– Mount the engine control module into risthe retaining
e
frame and tee
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push it in the direction of -arrow- upward.
aut or
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nl
pt
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an
– Install the windshield wiper arms, the plenum chamber cover
itte
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and the plenum chamber bulkhead. Refer to ⇒ Body Exterior;
ab
ility
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er .
, is n
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hole
Passat CC:
spec
es, in part or in w
– Install the windshield wiper arms and plenum chamber cover.
t to the co
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Trim Moldings and
rrectness of i
l purpos
nform
mercia
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c
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s
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7 Engine Control Module - J623- , Ti‐
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page 507 .
spec
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agen
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– Disconnect the connector -1- from the Windshield Defogger

Control Module - J505- .
– Remove the mounting frame with engine control module from
the plenum chamber.
– Press the locking mechanisms -1- outward and slide engine

control module -2- in the direction of -arrow-.
7. Engine Control Module J623 , Tiguan 507

AG. Volkswagen AG d
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– Slide the engine control module -1- in the direction of -arrow-
ility
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into mounting frame.
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ole,
spec
to bracket -4-.
t to the co
Tightening specifications for the bracket mounting nuts -4-: 6 Nm
– Tighten the bolts -3- to 7 Nm.
rrectne
the catches -2- toward the inside.
ss o
– Connect the connector -1- to the Windshield Defogger Control
cial p
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Module - J505- .
nform
mer
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
atio
m

o
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♦ Locking pliers
Removing
– Remove windshield wiper arms. Refer to ⇒ Rep. Gr. 92 ;
ling .
er .
– Cover the plenum chamber with a clean cloth so that it does
not get scratched.
– Raise the engine control module with frame slightly.

– Release engine control module in the direction of -arrow- and

pull it out slightly.
– Bend the raised ends -1- of locking bracket outward.

– Remove the shear bolts -2- with locking pliers and remove the
locking bracket.
AG. Volkswagen AG d
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– Remove the engine control module.
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Installing:
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– Slide the engine control module -1- in direction of -arrow- into

m
the mounting frame until it engages.

a
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tion in
– Tighten the mounting frame.

r
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Tightening specification: 6 Nm
do
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the catches -1- inward.
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7. Engine Control Module J623 , Tiguan 509

– Take a new locking bracket and tighten new shear bolts evenly
until bolt heads shear off.
AG. Volkswagen AG d
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8 Engine Control Module - J623- , Scir‐

occo through 11/2008
page 511 .

Installing
If the engine control module will be Areplaced,
G. Volkswagconnect
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Diagnostic Tester and perform agen
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does
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nl
pt
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an
– Remove windshield wiper arms. Refer to ⇒ Rep. Gr. 92 ;
itte
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ab
ling .
ility
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spec
es, in part or in w
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t to the co
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nform
mercia
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ate
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for
– Push the retainers in the -direction of the arrow- and discon‐

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nect the connector.
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8. Engine Control Module J623 , Scirocco through 11/2008 511


the retainers all the way in -the direction of the arrow-.
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nl
pt
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– Mount the engine control module into the retaining frame and
itte
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push it in the -direction of arrow- upward.
ab
ility
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– Install the plenum chamber bulkhead. Refer to ⇒ Body Exte‐
wit
, is n
rior; Rep. Gr. 50 ; Bulkhead; Overview - Bulkhead .
h re
hole
spec
es, in part or in w
t to the co
ling .
rrectness of i
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Removing Cop py
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– Remove windshield wiper arms. Refer to ⇒ Rep. Gr. 92 ; Prote AG.
ling .
terior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum Chamber
Cover .
– Push the retaining frame in -direction of arrow- downward and

– Remove the shear bolts -arrows- with locking pliers and re‐
move locking bracket.
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pt
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– Push the retainers in the -direction of the arrow- and discon‐
ab
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Installing
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spec
es, in part or in w
t to the co
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nform
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the retainers all the way in -the direction of the arrow-.
n
c
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Cop py
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rig ht
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Prote AG.
– Place both locking brackets on the connectors and secure it

with the shear bolts -arrows-.
– Tighten the shear bolts evenly until the bolt heads break off
-arrows-.
8. Engine Control Module J623 , Scirocco through 11/2008 513

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AG n AG d
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– Mount the engined bcontrol
yV module into the retaining frame
gu
ara and
push it in the -direction
rise of arrow- upward. nte
utho eo
r
– Install thessplenum
a
chamber bulkhead. Refer to ⇒ Body Exte‐ac
rior; Rep. Gr. 66 ; Trim Moldings and Trim; Plenum Chamber
ce
e
nl
pt
Cover .
du
an
itte
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ab
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spec
es, in part or in w
t to the co
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4-Cylinder Fuel Injection. VEngine
olkswage(1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015
AG n AG d
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9 Special Tools tho
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Special tools and workshop e
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equipment required
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♦ Torx Socket - T30 -
ility
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T10347-
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♦ Wrench - Oil Filter - 3417-
hole
spec
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t to the co
5-50Nm - VAG1331-
rrectness of i
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at
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c
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♦ Elbow Assembly Tool -

T10118- wage
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♦ Double Hexagoned Socket -
by ara
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27mm - VAS5301/7-
thoris eo
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♦ Coolingss System Charging c
ce
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Unit - VAS6394/1-
un
pt
an
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♦ Pressure Sensor Tester -
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Adapter - VAS6394/2-
ility
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♦ Pressure Sensor Tester -
is n
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Adapter VAS6394/4 -
ole,
spec
VAS6394/4- (only Tiguan)
t to the co
♦ Vehicle Diagnostic Tester -
Test Adapter - 3 Pin -
VAS5570-
rrectne
5-50Nm - VAG1331-
ss o
cial p
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VAS6122-
form
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♦ Window Cutter - VAG1561A-
♦ Saw Set - VAG1561/14-

♦ Hot air gun from Wiring Harness Repair Set - VAS1978B- .
AG. Volkswagen AG d
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♦ Ultrasonic Cleaning Unit - VAS6418-

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♦ Mounting Plate for Injection Modules - VAS6418/1-

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♦ Cleaning Fluid - VAS6418/2-
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Prote AG.

26 – Exhaust System, Emission Controls

1 Exhaust System, Passat and CC
⇒ “1.2 Overview - Exhaust System, Engine Code CCTA”,
page 521 .
olkswagen AG
en AG. V
⇒ “1.3 Overview - Exhaust System, Engine Code CBFA”, ksw
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page 523 . ed
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⇒ “1.4 Center Muffler and Rear Muffler, Separating”,au
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page 525 . ss c
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⇒ “1.5 Exhaust System, Installing without Tension”, page 526 .
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⇒ “1.6 Clamping Sleeve, Installation Position and Tightening
erm
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Specification”, page 527 .
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⇒ “1.7 Catalytic Converters with Front Exhaust Pipe, Removing
h re
hole
spec
es, in part or in w
⇒ “1.8 Exhaust System, Checking for Leaks”, page 530 .
t to the co
1.1 Overview - Exhaust System, Engine Co‐
des BZB, CAWA, CAWB and CGYA
rrectness of i
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Note
nf
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♦ The decoupling element in front exhaust pipe must not be bent
m
m
atio
more than 10 °, otherwise it may be damaged.
om
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♦ Replace the seals and self-locking nuts.
thi
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♦ After exhaust system repairs, make sure exhaust system is
o
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not under stress and is far enough from the body. If necessary,
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loosen clamping sleeve and align muffler and exhaust pipe so

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that there is adequate distance to body and that weight is
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evenly distributed among the suspended mounts.
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♦ The exhaust manifold and turbocharger are one component.
cted agen
Prote AG.
Refer to
⇒ “1.3 Turbocharger, Removing and Installing”, page 427 for
removing and installing.
518 Rep. Gr.26 - Exhaust System, Emission Controls

1 - 25 Nm
2 - Mount
3 - Seal
❑ Always replace
4 - 40 Nm
❑ Always replace
❑ Coat the stud bolts on
exhaust manifold with
hot bolt paste.
❑ Hot Bolt Paste - G 052
112 A3-
5 - Front Exhaust Pipe with
Catalytic Converters
Caution
Danger of causing dam‐
age to the decoupling el‐
ement.
Do
♦ not bend the decou‐
pling element more than
10°.
Do
♦ not stretch the decou‐ agen
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pling element. by
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Do
♦ not damage the wire horis
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❑ Protect catalytic con‐
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verter from shocks and
pe
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impact stress
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ling. Refer to
⇒ “1.7 Catalytic Converters with Front Exhaust Pipe, Removing and Installing”, page 528 . spec
es, in part or in w
t to the co
❑ Exhaust System, Installing without Tension. Refer to
rrectness of i
6 - Heated Oxygen Sensor - G39-

❑ Bank 1, sensor 1
l purpos
❑ 55 Nm
❑ Thread of new oxygen sensors is coated with hot bolt paste.
nform
ercia
❑ When using the previous oxygen sensor, grease only the threads with hot bolt paste; the paste must not
m
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ion in
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❑ Hot Bolt Paste - G 052 112 A3-

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8 - Mount C py
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❑ Replace if damaged p by
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9 - Rear Muffler Prote AG.
❑ Original equipment one unit with the center muffler. If a repair is required replace each separately
❑ Exhaust System, Separating. Refer to
⇒ “1.4 Center Muffler and Rear Muffler, Separating”, page 525 .
1. Exhaust System, Passat and CC 519

10 - Threaded Connection
❑ Tighten the threaded connections evenly. Tightening specification and installation position. Refer to
⇒ “1.6 Clamping Sleeve, Installation Position and Tightening Specification”, page 527 .
11 - Rear Clamping Sleeve
❑ For individual replacement of center and rear mufflers
12 - Center Muffler
❑ Original equipment as one unit with the rear Amuffler.
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gen G AG do
❑ Exhaust System, Separating. ReferVotolkswa es n
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⇒ “1.4 Center Muffler and ReareMuffler,
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13 - Threaded Connection au
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14 - Front Clamping Sleeve
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15 - Mount
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❑ For the center muffler
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1.2 Overview - Exhaust System, Engine Code CCTA
1 - Bolt
❑ 25 Nm
2 - Mount
3 - Seal
❑ Always replace
4 - Nut
❑ 40 Nm
❑ Always replace
hot bolt paste.
112 A3-
5 - Heated Oxygen Sensor -
G39-
❑ 55 Nm
❑ Thread of new oxygen
sensors is coated with
hot bolt paste.
❑ When using the previ‐
ous oxygen sensor,
grease only the threads
with hot bolt paste; the
paste must not get into
slots of oxygen sensor agen
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❑ Hot Bolt Paste - G 052 rised
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112 A3- aut
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10°.
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Do
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pling element.
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❑ Protect catalytic converter from shocks and impact stress

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⇒ “1.7 Catalytic Converters with Front Exhaust Pipe, Removing and Installing”, page 528 .
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7 - Oxygen Sensor after Three Way Catalytic Converter - G130- rig ht
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co Vo
❑ 55 Nm
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8 - Retaining Loop rise nte
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❑ Replace if damaged au ra
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9 - Mount
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10 - Rear Muffler
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spec
t to the co
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ss
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cial p
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mer
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13 - Center Muffler
o
n
c
i
or
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❑ Original equipment as one unit with the rear muffler. If a repair is required replace each separately
thi
te
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14 - Threaded Connection . Cop py
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❑ Tighten the threaded connections evenly. Tightening specification and installation position. Refer to rig ht
py by
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by lksw
cted agen
Prote AG.
16 - Mount

1.3 Overview - Exhaust System, Engine Code CBFA
1 - Bolt
❑ 25 Nm
2 - Mount
❑ Replace if damaged AG. Volkswagen AG d
agen oes
lksw not
3 - Seal byV
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ara
ed
❑ Always replace horis nte
eo
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4 - Nut ss c
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❑ 40 Nm
un
pt
an
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itte
❑ Always replace
y li
erm
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ility
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hot bolt paste.
h re
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spec
112 A3-
t to the co
5 - Heated Oxygen Sensor -
G39-
rrectne
❑ 55 Nm
ss o
❑ Thread of new oxygen
cial p
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sensors is coated with
nform
hot bolt paste.
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atio
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❑ When using the previ‐

o
n
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ous oxygen sensor,
i
or
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grease only the threads
te
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with hot bolt paste; the

i
o
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um
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slots of oxygen sensor

t.
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body Cop py
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rig ht
py by
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112 A3- by c lksw
cted agen
Prote AG.
Caution
ement.
Do
10°.
Do
♦ not stretch the decou‐
pling element.
Do
♦ not damage the wire
mesh on the decoupling
element.
❑ Protect catalytic converter from shocks and impact stress

⇒ “1.7 Catalytic Converters with Front Exhaust Pipe, Removing and Installing”, page 528 .
7 - Heated Oxygen Sensor 2 - G108-
❑ 55 Nm

8 - Oxygen Sensor after Three Way Catalytic Converter - G130-
❑ 55 Nm
❑ Bank 1, Sensor 3
9 - Retaining Loop
10 - Mount
11 - Rear Muffler
❑ Exhaust System, Separating. Refer to wage
es n
s
⇒ “1.4 Center Muffler and Rear Muffler, Separating”,
y V page 525 .
olk ot g
u b ara
ed n
12 - Threaded Connection tho
ris tee
or
u
❑ Tighten the threaded connections evenly. ss Tightening specification and installation position. Refer
a ac
to
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
14 - Center Muffler
es, in part or in w
t to the co
❑ Original equipment as one unit with the rear muffler. If a repair is required replace each separately
rrectness of i
l purpos
nform
ercia

m
a
com
ion in
r
te o
thi
s
iva
17 - Mount
do
r
rp
cum

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

1.4 Center Muffler and Rear Muffler, Sepa‐

rating
Note
♦ A separating point has been provided in the connecting pipe

for removing, installing and individual replacement of the cen‐
ter or rear muffler.
♦ The separating point is marked by an indentation around the
circumference of the exhaust pipe.

♦ Pneumatic Body Saw - VAS6780-
or
♦ Chain Pipe Cutter - VAS6254-
WARNING
To prevent injuries from metal shavings, wear protective gog‐

gles and protective clothing.
– Separate the exhaust pipe at a right angle at the separating

point -arrow- using, for example the Pneumatic Body Saw -
VAS6780- .
– Position the clamping sleeve at side markings when installing.
wage
e ks s no
Vol t gu
d by ara
e nte
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ra
a c
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erm
ab
ility
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– When installing the clamping sleeve, ensure that the bolt end
hole
spec
does not project over the lower edge of the clamping sleeve.
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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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
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byV ua
d ran
ir se
CC 2010 ➤ , Eos 2006 ➤ , Golfth 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...tee o
o
au ra
ss (1.8L and 2.0L Engine, Chain Drive) - Edition 07.2015 c
ce
e
nl
pt
du
– Align exhaust system so that distance -a- is equal at right and
an
itte
y li
left sides.
erm
ab
ility
ot p
Tightening specification:
wit
, is n
h re
Clamping sleeve with 2 individual clamps, 25 Nm.
hole
spec
Clamping sleeve with continuous clamp, 35 Nm. es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1.5 Exhaust System, Installing without Ten‐

m
sion
at
om
ion
c
in t
or
• Align the exhaust system when it is cold.
his
ate
do
riv
– Loosen the connections -3 and 4- on the front clamping sleeve

p
cum
or
-1-.
f
en
ng
t.
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op
– Align the front clamping sleeve -1- to marking -A- on the front C py
t. rig
exhaust pipe -2- (-arrow- faces in direction of travel). gh ht
pyri by
Vo
co lksw
by
• Dimension -a- =. Refer to Prote
cted AG.

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Service

Repair Manual Volksw

CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ ,

Passat CC 2009 ➤ , Tiguan 2008 ➤

Service Department. Technical Information

26 - Exhaust System, Emission Controls

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E800F5F31

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.2 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.3 Crankshaft Bearing Shells, Allocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.1 Overview - Timing Chain Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.2 Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.4 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1.5 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

CCZC, CCZD, CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

3.3 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

CDAA, and CDAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.1 Overview - Oil Filter and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

4.3 Oil Pressure Switch F1 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

4.5 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

3.2 Radiator Identification Sensor G611 , Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

3.4 Fan Shroud, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3.7 Radiator, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

8.2 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

1.2 Hose Connections with Connector Couplings, Assembling . . . . . . . . . . . . . . . . . . . . . . . . 426

1.3 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

1.4 Turbocharger Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

1.6 Turbocharger Vacuum Diaphragm, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 438

2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

2.2 Overview - Charge Air Cooling System, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

2.5 Overview - Turbocharging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

2.8 Charge Air Cooler, Removing and Installing, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

2.10 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

OBD General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

2 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

2.2 Overview - Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

2.5 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465

2.12 Fuel Injectors, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

2.15 Throttle Valve Control Module J338 , Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

2.17 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518

1.1 Ignition System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

1.3 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

1.5 Knock Sensor 1 G61 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

1.6 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

1.7 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

00 – General, Technical Data

Vehicle data label locations. Refer to ⇒ Maintenance ; Booklet

Torque Nm at RPM 280/1700 280/1700

Stroke mm 92.8 92.8