4 Cylinder Diesel Engine 2.0L Engine Common Rail Repair Manual Edition 04.2015 PDF

Service
Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
4-Cylinder Diesel Engine (2.0L Engine, Common Rail)
Engine ID
CBE CJAA
A
ProCarManuals.com
Edition 04.2015
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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
20 - Fuel Supply
21 - Turbocharger, Supercharger
23 - Diesel Fuel Injection
26 - Exhaust System, Emission Controls
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 © 2016 Volkswagen AG, Wolfsburg D3E80109914

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
4-Cylinder Diesel Engine (2.0L Engine, Common Rail) - Edition 04.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Transmission and Engine, Disconnecting and Assembling . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Engine, Securing to Engine and Gearbox Bracket VAS6095A . . . . . . . . . . . . . . . . . . . . . . 13
1.4 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Subframe Mount, except Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Engine-Subframe Mount Adjustment, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Subframe Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Assembly Mounts, Jetta from 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Transmission Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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3.4 Pendulum Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.5 Engine, Supporting in Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Subframe Mount, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.7 Subframe Mount, Checking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1 Engine, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Overview - Toothed Belt Drive agen. . . . . . . . . . . A
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1.3 Overview - Cylinder Block y Vo . . . . . . . . . . . . . . . . . . . . .o.t g.u.a . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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1.4 Ribbed Belt, Removing
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1.5 Ribbed Belt Tensioner,
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1.6 Sub-Assembly Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.7 Engine Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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2 Sealing Flange and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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2.1 Overview - Sealing Flange and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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2.2 Crankshaft Sealing Flange, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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2.3 Crankshaft Seal, Replacing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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2.4 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 64

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2.5 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3 Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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3.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.2 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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3.3 Bearing Shells - Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.4 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.5 Piston Projection in Top Dead Center (TDC), Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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4.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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4.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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4.3 Needle Bearings, Removing and Installing from Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 75

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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Overview - Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Overview - Cylinder
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1.6 Toothed Belt, Removing, Installing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1.7 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.8 Vacuum Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.9 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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2 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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2.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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2.2 Camshafts, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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2.3 Camshaft Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.4 Valve Stem Seals with Cylinder Head Installed, Replacing . . . . . . . . . . . . . . . . . . . . . . . . 138
2.5 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1.1 Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1.2 Engine Oil, Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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2 Lubrication System Components, Engine Code CBEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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2.1 Overview - Oil Pump, Oil Pan and Balance Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . 153
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2.2 Oil Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.3 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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2.4 Balance Shaft Assembly, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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2.5 Spur Gear, Removing from Crankshaft and Shrink-Fitting New Spur Gear . . . . . . . . . . . . 166
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3 Lubrication System Components, Engine Code CJAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Overview - Oil Pump and Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Oil Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4 Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line . . . . . . . . . . . . . . . . . . . . . . 177
4.1 Overview - Oil Filter Bracket and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.2 Oil Filter Bracket with Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 179
4.3 Oil Supply Line to Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4 Oil Pressure and Oil Pressure Switch F1 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.1 Overview - Cooling System Components, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.2 Cooling System Components, Engine-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.3 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.4 Air Shroud with Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing . . . . 202
1.5 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.6 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.7 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.8 4/2-Way Valve with Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . 205
1.9 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.10 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.11 Oil Cooler, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
1.12 Engine Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 223
2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3 Misfueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.1 Step 1 (Engine Was Started with Incorrect Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.2 Step 2 (Engine Was Not Started with Incorrect Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.3 Step 3 (Shavings in the Fuel Delivery Unit and Reservoir) . . . . . . . . . . . . . . . . . . . . . . . . 227
3.4 Step 4 (No Shavings in the Fuel Delivery Unit and Reservoir) . . . . . . . . . . . . . . . . . . . . . . 228
3.5 Step 5 (Shavings in the High Pressure Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.6 Step 6 (No Shavings in the High Pressure Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4 Fuel Supply System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.2 Overview - Fuel Tank, All Vehicles Except Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . 231
4.3 Overview - Fuel Tank, Jetta from MY 2011 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.4 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.5 Fuel Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.6 Fuel Delivery Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.7 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5 Connector Couplings, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
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6 Fuel Supply System, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

6.2 Overview - Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.3 Fuel Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.4 Transfer Fuel Pump G6 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.5 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6.6 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing and Installing . . . . . . . . . . . . . . 259
7 Electronic Engine Output Control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1 EPC System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.2 Overview - Accelerator Pedal Module . . . . n.A.G.. V . o. lk. s.w.a.ge. n.A.G. . . . . . . . . . . . . . . . . . . . . . . . 262
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7.3 Accelerator Pedal Module, Removing oland
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8 Special Tools . . . . . . . . . . . . r.ise. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . 265
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ss .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
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1 Safety Precautions when Working on Charge Air System And Turbocharger . . . . . . . . . . 268
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2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

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3 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
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3.1 Overview - Turbocharger with Exhaust Manifold and Attachments . . . . . . . . . . . . . . . . . . 270

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3.2 Turbocharger with Exhaust Manifold, Removing and Installing, Engine Codes CBEA,
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CJAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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3.3 Turbocharger with Exhaust Manifold, Removing and Installing, Engine Codes CBDA, CBDB,
CEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3.4 Vacuum Diaphragm with Charge Air Pressure Actuator Position Sensor G581 , Replacing
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........................................................................ 282
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4 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

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4.2 Overview - Charge Air Cooler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

4.3 Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and
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Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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4.4 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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4.5 Vacuum Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

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4.6 Vacuum Hose Connection Diagram, Engine Codes CBDA, CBDB, CEGA . . . . . . . . . . . . 296
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4.7 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

1 Safety Precautions when Working on Diesel Direct Fuel Injection System . . . . . . . . . . . . 303
2 Guidelines for Clean Working AGConditions
. Volkswagen AG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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3 Diesel Direct Injection o lkswSystem . . . . . . . . . . . .s n. o.t g. u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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3.1 General Information
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3.2 System Overview
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3.3 Overview s - Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . .
s
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3.4 Fuel Injector (Piezo Injector), Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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3.5 Fuel Pressure Regulator Valve N276 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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3.6 Fuel Pressure Regulator Valve N276 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 322
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3.7 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
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3.8 High Pressure Fuel Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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3.9 Fuel System, Filling/Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
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3.10 Fuel System, Performing Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.11 Pressure Retaining Valve in Fuel Return, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3.12 Overview - Intake Manifold with Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
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3.13 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.14 Overview - Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
ss
3.15 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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3.16 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
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3.17 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
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4 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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4.1 Engine Control Module J623 without Anti-Theft Protection, Removing and Installing, All
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4.2 Engine Control Module J623 with Anti-Theft Protection, Removing and Installing, All Vehicles
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4.3 Engine Control Module J623 , Removing and Installing, Jetta from MY 2011 Only . . . . . . 347
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5 Engine Control Module, Engine Codes CBDA, CBDB, CEGA . . . . . . . . . . . . . . . . . . . . . . 350
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5.2 Engine Control Module J623 with Anti-Theft Protection, Removing and Installing . . . . . . 351
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

1 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
1.2 Overview - Particulate Filter with NOx Reduction Catalytic Converter . . . . . . . . . . . . . . . . 360
1.3 Clamps and Exhaust Gas Temperature Sensor Installed Position . . . . . . . . . . . . . . . . . . 368
1.4 Particulate Filter with NOx Absorption Catalytic Converter, Removing and Installing . . . . 369
1.5 Overview - Exhaust Flap Control Module J883 with Slip Catalyst . . . . . . . . . . . . . . . . . . . . 376
1.6 Exhaust System Component Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
1.7 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
1.8 Exhaust System, Disconnecting and Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
1.9 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.10 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
2 Exhaust System, Engine Codes CBDA, CBDB and CEGA . . . . . . . . . . . . . . . . . . . . . . . . 388
2.1 Overview - Front Exhaust Pipe with Particulate Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
2.2 Particulate Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
2.3 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
2.4 Exhaust Pipe, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
2.5 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3 EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3.1 Overview - Exhaust Gas Recirculation System Components . . . . . . . . . . . . . . . . . . . . . . 398
3.2 EGR Temperature Sensor G98 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 399
iv Contents
4 EGR System, Engine Codes CBDA, CBDB and CEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

4.1 Overview - Exhaust Gas Recirculation System eComponents . Volkswagen.A.G. . . . . . . . . . . . . . . . . . . . 403
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5 Special Tools . . . . . . . . . . . . . . . . . .b.y .Vo. lk. . . . . . . . . . . . . . . . . . . . . n. o.t .gu. . . . . . . . . . . . . . . 405
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28 - Ignition/Glow Plug System . . . a.ut . . . .
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1 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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1.2 Glow Plug, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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1.3 Glow Plug Connectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
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3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
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Contents v
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vi Contents
00 – General, Technical Data

1 Technical Data
(Edition 04.2015)
⇒ “1.1 Engine Number”, page 1 .
⇒ “1.2 Engine Specifications”, page 1 .
1.1 Engine Number

♦ Four-letter engine codes were introduced in MY 2008.
♦ The first three positions describe the mechanical engine struc‐
ture. They are stamped on the engine. The fourth position
describes the engine output and depends on the Engine Con‐
trol Module - J623- .
♦ The four-letter engine code is on the type label, the vehicle
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♦ The vehicle data label is located in both the tcustomer
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♦ The engine number (“engine code” and “serial number”) are
located at the engine/transmission joint -arrow-.
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♦ A sticker with the “engine code” and “serial number” is also on
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♦ The engine number consists of up to nine characters (alpha‐
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1.2 Engine Specifications
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Codes CBEA CJAA
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Manufactured from 04/2008 from 05/2009
Emissions values in accordance with LEV II standard ULEV2 Standard
Displacement liters 2.0 2.0
Output kW at RPM 103/4000 103/4000
Torque Nm at RPM 320/1750 to 2500 320/1750 to 2500
Bore Diameter in mm 81.0 81.0
Stroke mm 95.5 95.5
Valves per cylinder 4 4
Compression ratio 16.5 16.5
Diesel fuel in accordance with ASTM D 975 Standard1) ASTM D 975 Standard1)
Ignition sequence 1-3-4-2 1-3-4-2
Balance Shaft Assembly yes no
1. Technical Data 1
Codes CBEA CJAA

NOx Reduction Catalytic Converter yes yes
Slip Catalyst yes yes
Exhaust Gas Recirculation (EGR) yes yes
Turbocharger, Supercharger yes yes
Charge Air Cooler yes yes
Particulate Filter yes yes
1) with a sulfur content less than 15 mg/kg of diesel fuel
AG. Volkswagen AG d
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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 12
⇒ “1.3 Engine, Securing to Engine and Gearbox Bracket
VAS6095A ”, page 13
⇒ “1.4 General Installation Information”, page 14
1.1 Engine, Removing olkswage

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When doing any assembly work, especially in the engine com‐
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♦ Route all lines and wires in their original locations.
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♦ For example, for fuel lines, hydraulic lines, EVAP system
hole
lines, coolant and refrigerant lines, brake fluid lines and
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vacuum lines.
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♦ Make sure that there is sufficient clearance to all moving
or hot components.
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Special tools and workshop equipment required

♦ Lifting Tackle - 3033-
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♦ Hose Clamps - Up To 25mm - 3094- (vehicles with manual
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♦ Torque Wrench 1331 5-50Nm - VAG1331-
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♦ Step Ladder - VAS5085-

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♦ Shop Crane - VAS6100-
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♦ Shop Crane - Drip Tray - VAS6208-
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♦ Hose Clip Pliers - VAS6362-
♦ Transportation Lock - T10404-
♦ Engine Bung Set - VAS6122- (not illustrated)
DANGER!
♦ Follow the safety precautions when working on the diesel

direct fuel injection system. Refer to
⇒ “1 Safety Precautions when Working on Diesel Direct
Fuel Injection System”, page 303 .
♦ Pay attention to the guidelines for clean working condi‐
tions. Refer to
⇒ “2 Guidelines for Clean Working Conditions”,
page 305 .
Always pay attention to these instructions before and during
work.
1. Engine, Removing and Installing 3

Note
♦ Subframe mount. Refer to

⇒ “2 Subframe Mount, except Jetta from MY 2011”,
page 17 .
♦ Overview - Body Side Cooling System Components. Refer to
⇒ “1.1 Overview - Cooling System Components, Body Side”,
page 190 .
♦ Overview - Fuel Filter. Refer to
⇒ “6.2 Overview - Fuel Filter”, page 249 .
♦ Overview - Turbocharger with Exhaust Manifold and Attach‐
ments. Refer to
⇒ “3.1 Overview - Turbocharger with Exhaust Manifold and
Attachments”, page 270 .
♦ Overview - Charge Air Cooler Components. Refer to
⇒ “4.2 Overview - Charge Air Cooler Components”,
page 290
♦ Overview - Particulate Filter with NOx Reduction Catalytic
Converter. Refer to
⇒ “1.2 Overview - Particulate Filter with NOx Reduction Cat‐
alytic Converter”, page 360 .
olkswagen AG
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♦ Overview - EGR Components.olkRefer
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⇒ “3.1 Overview - Exhaust d Gas
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♦ Always replace clamp-type clips with spring-type clips.

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♦ Hose Clip Pliers - VAS6362- or the Hose Clip Pliers -

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VAS6340- are recommended for installing spring clips.

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♦ The Battery - A- ground cable must be disconnected for the

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following procedure. For this reason check if a coded radio is

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installed. If necessary, obtain anti-theft code beforehand.

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♦ All cable ties which are opened or cut open when removing
engine, must be replaced in the same position when installing
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♦ The engine is removed forward together with the transmission.

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Requirements
• Ignition switched off.
• Engine must be cold.
4 Rep. Gr.10 - Engine Assembly

Procedure
– Check the DTC memory for all control modules before remov‐
al. Refer to Vehicle Diagnostic Tester “Vehicle Self-Diagno‐
sis”.
– Remove the engine cover. Refer to
⇒ “1.4 Engine Cover, Removing and Installing”, page 90 .
– Remove the air filter housing. Refer to
⇒ “3.14 Overview - Air Filter”, page 335 .
– Remove the intake hose between the Mass Airflow Sensor -
G70- and the intake scoop. Loosen the spring clamps using
the Hose Clip Pliers - VAS6362- .
Caution
Electronic components could be destroyed when the Battery -

A- is disconnected:
♦ Complete the steps for disconnecting the Battery - A- .
– When the ignition is switched off, disconnect the ground cable

-arrow- from the Battery - A- . Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
ProCarManuals.com
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– Release the pass-through for the engine wiring harness -A- in

direction of -arrow- and pull it off upward.
– Remove the E-box cover from the engine compartment by

sliding both latches in the direction of -arrows-.
ProCarManuals.com
– Disconnect the wire from the Generator - C- -A- and the wire
from the Battery - A- -B- at the fuse panel.
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– Disconnect -arrow- from the Starter - B- .

– Remove the ground wire from the transmission holder.
– Disconnect the connector for the Exhaust Gas Temperature

Sensor 2 - G448- -1-, the »black« connector for Exhaust Gas
Temperature Sensor 1 - G235- -2- as well as the connector for
the Heated OxygengeSensor
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– Disconnect the connector -2- from the Exhaust Pressure Sen‐

sor 2 - G451- -1-.
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– Disconnect the control wire from the Exhaust Pressure Sensor
1 - G450- . Loosen the spring clamp using the Hose Clip Pliers
- VAS6362- .
– Remove the bolts and bracket with the Exhaust Pressure Sen‐
sor 1 - G450- and lay them aside (the control wire to the
particulate filter remains connected).
– Rotate the Wastegate Bypass Regulator Valve - N75- out of
the holder and set it on the engine.

– Remove the screw -arrow- and move the windshield washer

fluid reservoir filler tube to the side.
– Remove the coolant reservoir and set it on the engine (coolant
hoses stay connected).
– Remove the fuel filter. Refer to
⇒ “6.3 Fuel Filter, Removing and Installing”, page 251 .
– Remove the Auxiliary Fuel Pump - V393- . Refer to
⇒ “6.6 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Remov‐
ing and Installing”, page 259 .
– Disconnect the vacuum hose from the brake booster.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Noise Insulation .
– Drain the coolant. Refer to
⇒ “1.9 Coolant, Draining and Filling”, page 209 .
– Disconnect the coolant hoses between the engine and radia‐
tor. Refer to
⇒ “1.1 Overview - Cooling System Components, Body Side”,
page 190 , Overview - Body Side Cooling System Compo‐
nents.
– Open the quick-release couplings for the heat exchanger

-arrows- on the plenum chamber bulkhead.
ProCarManuals.com
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– Disconnect the connecting hoses between the engine and the

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– Extract the refrigerant from the A/C system. Refer to ⇒ Heat‐
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ing, Ventilation and Air Conditioning; Rep. Gr. 87 .
spec
es, in part or in w
– Remove the refrigerant lines on the A/C compressor and con‐
t to the co
denser and secure them on the body without tension. Refer to
⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 .
rrectness of i
– Remove the lock carrier. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Lock Carrier; Lock Carrier with Attachments, Removing
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and Installing .
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– Remove the right drive axle heat shield -arrows-.

– Dismount the drive axles only from the transmission. Refer to
⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,
Removing and Installing .
Caution
The decoupling elements between the particulate filter and

NOx reduction catalytic converter can be damaged. When re‐
moving and installing:
♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling element.
♦ Use the Transportation Lock - T10404- to secure the de‐
coupling element from stretching.
– Remove the lower bracket for the particulate filter.

– Remove the exhaust gas recirculation filter -item 9-
⇒ Item 9 (page 399) .
ProCarManuals.com
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Remove the nuts above the bracket with the Wrench - Sw13 - wagen AG. Volkswagen AG doe
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late filter. Loosen the bracket on the cylinder head.
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– Loosen the clamp -1- between the particulate filter and the
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– Secure the particulate filter without tension on the body.

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– Remove the shift mechanism from the transmission. Refer to

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– Remove the clamp -arrow- for the hydraulic clutch hydraulic
line -A- all the way.
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– Pull the hydraulic line -A- out of the breather/slave cylinder and
seal it off.
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– Remove/disconnect all wires necessary from engine/trans‐
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mission and free them up.
Note
Verify that all hose and line/wire connections between the engine,
transmission and body have been disconnected.
– Remove the bolts -1 to 3- and then remove the pendulum sup‐

port.

– Engage the Lifting Tackle - 3033- as follows and support the

»Engine/transmission assembly« in its installation position us‐
ing the Shop Crane - VAS6100- .
Vibration damper side:
• item 2
Flywheel side:
• item 8
– Remove the subframe bolts -arrows- on the engine.

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– Remove the subframe bolts -arrows- on the transmission.

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– Separate the transmission from the engine. Refer to
⇒ “1.2 Transmission and Engine, Disconnecting and Assem‐
bling”, page 12 .
Secure the engine on the Engine and Gearbox Bracket -
VAS6095A- when performing repair work. Refer to
⇒ “1.3 Engine, Securing to Engine and Gearbox Bracket
VAS6095A ”, page 13 .

1.2 Transmission and Engine, Disconnect‐

ing and Assembling
Disconnecting:
WARNING

space.
vacuum lines.
or hot components.

♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
Conditions
ProCarManuals.com
• The »engine/transmission assembly« is removed.

Procedure
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
Engine with DSG® Transmission:
– Remove the coolant hoses from the transmission fluid cooler
and seal off the openings. agen
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mission and the engine. ss c
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– Secure the transmission with Engine/Gearbox Support Shack‐

le (2 pc.) - 10-222A/12- on the Shop Crane - VAS6100- but do
not lift.
– Remove the upper engine/transmission connecting bolts.
– Before removing the last connecting bolts, support the trans‐
mission with the Shop Crane .
– Remove the lower engine/transmission connecting bolts.
– Separate the transmission from the engine; when doing this,
guide the transmission.
Assembling:
WARNING
olkswagen AG
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When doing any assembly work, especially in the engine
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Assembly is performed in reverse order of removal; at the same
time pay attention to the tightening specifications:
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• Vehicles with manual transmission. Refer to ⇒ 6-Speed Man‐
ual Transmission 02Q; Rep. Gr. 34 .
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• Vehicles with DSG® transmission. Refer to ⇒ 6-Speed Dual

Clutch Transmission 02E; Rep. Gr. 34 .
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1.3 Engine, Securing to Engine and Gear‐
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vacuum lines.
or hot components.

♦ Engine and Gearbox Bracket VAS6095A - VAS6095A-
For performing assembly work, secure the engine using the En‐
gine/Transmission Holder - Universal Mounting - VAS6095/1- to
the Engine and Gearbox Bracket - VAS6095A- .

Conditions
• Transmission must be disconnected from the engine.
Procedure
– Engage the Lifting Tackle - 3033- as follows and lift up with the
Shop Crane - VAS6100- .
Flywheel side:
• item 4
Vibration damper side:
• item 8
– Fasten the engine to the Engine/Transmission
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1.4 General Installation Information
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♦ For example, for fuel lines, hydraulic lines, EVAP system t to the co
lines, coolant and refrigerant lines, brake fluid lines and rrectne
vacuum lines.
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or hot components.
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Install in reverse order of removal. Note the following:

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♦ Vehicles with manual transmission. Refer to ⇒ 6-Speed Man‐

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♦ Vehicles with DSG® transmission. Refer to ⇒ 6-Speed Dual . Cop py
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– Check that the alignment bushings for centering the engine/
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transmission are installed inside the cylinder block. Install
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them if necessary.
– Make sure there is enough clearance to the subframe and ra‐
diator when installing the »engine/transmission assembly«.
– Adjust the subframe mount. Refer to
⇒ “2.3 Subframe Mount, Adjusting”, page 19 .
Note
♦ Subframe mount tightening specifications. Refer to

⇒ “2.1 Overview - Subframe Mount”, page 17 , Overview -
Subframe Mount.
♦ Electrical connections and routing. Refer to ⇒ Electrical
Equipment; Rep. Gr. 97 .


– Install the hydraulic clutch hydraulic line. Refer to ⇒ 6-Speed
Manual Transmission 02Q; Rep. Gr. 30 .
– Install the transmission shift mechanism and adjust it if nec‐
essary. Refer to ⇒ 6-Speed Manual Transmission 02Q; Rep.
Gr. 34 .
– Install the transmission selector lever cable and adjust it if
necessary. Refer to ⇒ 6-Speed Dual Clutch Transmission
02E; Rep. Gr. 34 .
The Additional Numbered Procedures Must Be Followed AG. Volkswagen AG d
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clamps.
spec
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Caution
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The decoupling elements between the particulate filter and
NOx reduction catalytic converter can be damaged. When re‐
moving and installing:
ss o
cial p
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inform
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atio
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coupling element from overbending.
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t.
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– Install the particulate filter with NOx reduction catalytic con‐
t. C rig
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verter and the EGR filter. Refer to p by
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⇒ “1.4 Particulate Filter with NOx Absorption Catalytic Con‐
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verter, Removing and Installing”, page 369 .
AG.
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐

pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing .

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– Install the right drive axle heat shield -arrows-.
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spec
Vehicles with DSG® transmission:
es, in part or in w
t to the co
• Tightening specification. Refer to ⇒ 6-Speed Dual Clutch
Transmission 02E; Rep. Gr. 34 .
rrectness of i
– Install the lock carrier. Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
Lock Carrier; Lock Carrier with Attachments, Removing and
l purpos
Installing
– Secure the refrigerant lines on the A/C compressor and con‐
nf
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denser without tension. Refer to ⇒ Heating, Ventilation and
rm
m
Air Conditioning; Rep. Gr. 87 .
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– Fill the A/C system. Refer to ⇒ Heating, Ventilation and Air

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Conditioning; Rep. Gr. 87 .
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– Install the Battery - A- and the battery tray. Refer to ⇒ Electrical
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System; Rep. Gr. 27 ; Battery; Battery Tray, Removing and
en
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t.
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Installing .
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⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Dis‐
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ProCarManuals.com
– Fill with coolant. Refer to

– Fill the fuel system. Refer to
⇒ “3.9 Fuel System, Filling/Bleeding”, page 328 .
– Check the DTC memories of all control modules and erase all
DTC entries which may have occurred during the assembly.
Refer to Vehicle Diagnostic Tester “Vehicle Self-Diagnosis”.
– Check the headlamp adjustment and adjust if necessary. Re‐
fer to ⇒ Maintenance ; Booklet 20.1 ; Procedure Descriptions .
Tightening Specifications
Threaded Connection Tightening Specification

Bolts and Nuts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm. Refer to 1).
1) Tightening specification for the M12 collar bolt: 75 Nm

2 Subframe Mount, except Jetta from

MY 2011
⇒ “2.1 Overview - Subframe Mount”, page 17
⇒ “2.2 Engine-Subframe Mount Adjustment, Checking”,
page 19
⇒ “2.3 Subframe Mount, Adjusting”, page 19
2.1 Overview - Subframe Mount
1 - Bolt
❑ For the transmission
holder to the transmis‐
sion
Tightening specification:
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3 - Engine Bracket
❑ Removing and instal‐
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ling. Refer to
⇒ “1.7 Engine Bracket,
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Removing and Instal‐

ling”, page 52 .
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4 - Bolt
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❑ 40 Nm + 1/2 (180 °) ad‐

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❑ For engine bracket to

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⇒ Fig. ““Engine Bracket
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to Cylinder Block Tight‐
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ening Sequence”“ , page 19 .

5 - Engine Mount
6 - Bolt
❑ 40 Nm + 1/4 (90 °) additional turn
❑ Replace
❑ For engine mount to body
7 - Bracket
8 - Bolt
2. Subframe Mount, except Jetta from MY 2011 17

❑ Replace
❑ For bracket to engine mount
9 - Bolt
❑ Replace
❑ For bracket to body
10 - Bolt
❑ Replace
❑ For engine mount to body agen
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ProCarManuals.com
❑ For pendulum support to subframe

14 - Bolt
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❑ 60 Nm + 90° (1/4 turn) additional turn
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❑ For transmission mount to transmission holder
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❑ Vehicles with manual transmission. Refer to ⇒ 6-Speed Manual Transmission 02Q; Rep. Gr. 34 .
❑ Vehicles with DSG® transmission. Refer to ⇒ 6-Speed Dual Clutch Transmission 02E; Rep. Gr. 34 .
18 - Transmission Holder

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2.3 Subframe Mount, Adjusting

♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-
♦ Engine Support Bridge - Gearbox Adapter - 10-222A/13-
Procedure
WARNING

space.
vacuum lines.
or hot components.



– Remove the intake hose between the Mass Airflow Sensor -
G70- and the intake scoop. Loosen the spring clamps using
the Hose Clip Pliers - VAS6362- .
Caution

A- is disconnected:

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nected). Refer to

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– Replace the engine mount bolts -arrows- one after the other
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– Loosen left and right support arm bolts approximately two
turns.


– Make sure that the edges on the support arm -1- and trans‐
mission mount -2- are parallel on the transmission side.
• Dimension -x- is the same size on both sides of the mount.
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Further installation is the reverse order of removal. Note the fol‐
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• Check the fuel lines for secure fit.
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⇒ “3.2 Engine Mount, Removing and Installing”, page 24
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⇒ “3.3 Transmission Mount, Removing and Installing”,
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⇒ “3.4 Pendulum Support, Removing and Installing”, page 30
⇒ “3.5 Engine, Supporting in Installation Position”, page 31
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⇒ “3.6 Subframe Mount, Adjusting”, page 35
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⇒ “3.7 Subframe Mount, Checking Adjustment”, page 36
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2 - Bolts
❑ 50 Nm + 90° (1/4 turn)
additional turn
❑ Replace after removing
❑ Pendulum support to
transmission
3 - Engine Support
4 - Bolt
❑ 40 Nm +180° (1/2 turn)
additional turn
❑ Engine support to en‐
gine
5 - Engine Mount
ling. Refer to
⇒ “3.2 Engine Mount,
ling”, page 24 .
6 - Bolt
❑ 40 Nm + 90° (1/4 turn)
additional turn
❑ Engine mount to body
7 - Bracket
8 - Bolt
❑ Bracket to engine mount
3. Assembly Mounts, Jetta from 2011 23

9 - Bolt
❑ Bracket to body
10 - Bolt
❑ Engine mount to body
11 - Bolts
❑ Engine mount to engine support
12 - Pendulum Support
❑ First install the pendulum support to the transmission and then to the subframe
13 - Bolt
❑ Pendulum support to subframe
ProCarManuals.com
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Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

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– Open the connectoredcouplings
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can reach up to 100 °C (212 °F) after stopping the engine.
spec
Let the fuel cool down before opening any line connec‐
tions, otherwise there is a danger of scalding.
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♦ Wear safety gloves.
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♦ Wear protective eyewear.
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– Unclip the coolant hose bracket -1-.
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– Free up the fuel lines.
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– Remove the fuel filter -7- from the mountings -1 through 3- and
lay it on the engine.
Note
Refer to ⇒ Fuel Supply - Diesel Engines; Rep. Gr. 20 ; Fuel Filter .
– Disconnect and disconnect for the coolant expansion tank

-2-.
– Remove the bolts -3- and the coolant expansion tank -2-.
– Unclip and free up the wire -1-.

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- G450- .
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– Seal the open lines and connections with clean plugs from the
Engine Bung Set - VAS6122- .
– Lay the Exhaust Pressure Sensor 2 - G451- with the bracket
on the particulate filter.

– Remove the bolt -1-.

– Push the filler tube and windshield wiper fluid reservoir filler
tube -2- to the side.
Note
Ignore -3-.
– Support the engine in the installation position. Refer to

⇒ “3.5 Engine, Supporting in Installation Position”,
page 31 .
– Tension the engine slightly via the spindles do not lift it.
– Remove the bolts -A- and the bracket.
– Remove the bolts -B and C-.
ProCarManuals.com
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– Remove the engine mount upward.

Installing
Caution
Risk of damaging threads in transmission support by inserting

bolts at an angle.
♦ The transmission support and the transmission mount
support arm must be absolutely parallel to each other be‐
fore installing the bolts. Push the rear nof
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cient clearance to all moving or hot components.
ProCarManuals.com
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♦ Refer to ⇒ “3.6 Subframe Mount, Adjusting”, page 35

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♦ Refer to ⇒ “3.1 Overview - Subframe Mount”, page 23

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♦ Fuel filter. Refer to ⇒ Fuel Supply - Diesel Engines; Rep. Gr. cted agen
Prote AG.
20 ; Fuel Filter .
♦ Battery tray. Refer to ⇒ Electrical System; Rep. Gr. 27 ; Bat‐
tery; Battery Tray, Removing and Installing .
♦ Plenum chamber cover. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Plenum Chamber Cover; Plenum Chamber Cover, Re‐
3.3 Transmission Mount, Removing and In‐

stalling
Removing
⇒ “1.1 Engine, Removing”, page 3 .

– Remove the battery and the battery tray. Refer to ⇒ Electrical

Installing .
– Remove the air filter housing with the Mass Airflow Sensor -
G70- and connecting pipe. Refer to AG. Volkswagen AG d
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⇒ “3.5 Engine, Supporting in Installation Position”, ac
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– Free up the wires at the cable guide.
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– Unclip the wiring guide -1- upward in direction of -arrows- and
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– Pretension the engine/transmission sub-assembly using the
spec
spindles, but do not lift it.
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Note
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Ignore -1 and 3-.
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bolts at an angle.
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ss
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page 290
♦ Plenum chamber cover. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Plenum Chamber Cover; Plenum Chamber Cover, Re‐
3.4 Pendulum Support, Removing and In‐

stalling
Removing
– Remove the bolts -2 and 3-.

– Remove the pendulum support.

Installing
Install in reverse order of removal. Note the following.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
AG. Volkswagen AG d
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♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Spindle - 10-222A/11-
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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
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♦ Rail with Holes - T40091/2- from the Engine Support - Basic
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♦ Engine Support - Basic Set - Movable Joint - T40091/3- (quan‐
tity: 2) from the Engine Support - Basic Set - T40091-
♦ Engine Support - Movable Joint - T40093/4- (quantity: 2) from
the Engine Support - Supplement Kit - T40093A-
Procedure
Caution
For all repair work, especially in the engine compartment due

to the tight working conditions, observe the following:
♦ Route all lines in their original locations.
♦ To prevent damage to the lines, make sure there is suffi‐

Caution
Risk of damaging the decoupling element:


⇒ “3.15 Air Filter Housing, Removing and Installing”,
page 338 .
System; Rep. Gr. 27 ; Battery; BatterywTray,
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– Disconnect the connector from the crankcase ventilation hose
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– Remove the bolts -arrows- for the left and right sides of the
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– Remove the lower mounts from the Engine Support Bridge -

Engine Support 28 - 10-222A/28- .
– Attach the Engine Support Bridge - Engine Support 28-2 -
10-222A/28-2- .
– Remove the bolts in direction of -arrows- for securing the en‐
gine support bridge on the lock carrier from the Engine Support
28-2 - 10-222A/28-2- .
Note
Use the bolts from the Engine Support Bridge - Engine Support
28-2 -10-222A/28-2- for attaching the Engine Support Bridge -
Engine Support 28 - 10-222A/28- . Do not use the bolts for the
retaining bracket.
– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts -arrows-.
• Bolt tightening specification -arrows- 8 Nm
Caution
ProCarManuals.com
A second technician is needed to mount the Engine Support

Bridge on the vehicle to prevent the Engine Support Bridge
from tipping.
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1 - Engine Support Bridge - En‐

gine Support 31 Adapter 31-2
- 10-222A/31-2-
2 - Engine Support - Basic Set
- Moveable Joint - T40091/3-
3 - Engine Support Bridge - En‐
gine Support 31 Adapter 31-1
- 10-222A/31-1-
- Rail with Holes - T40091/2-
5 - Engine Support - Supple‐
ment Kit - Movable Joint -
T40093/4-
- Square Pipe - T40091/1-
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9 - Engine Support Bridge -
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10 - Engine Support - Bracket
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– Tighten all bolted connections on the Engine Support Bridge
c
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hand-tight. While doing so, adjust the height of the Engine
his
ate
Support Bridge parallel over the Engine Support Bridge - En‐

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– Lightly pretension the engine/transmission assembly using the
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Remove the Engine Support Bridge.
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The removal of the engine support bridge is the reverse of instal‐
lation noting the following.
– Check the adjustment of the subframe mount, in case they
were loosened. Refer to
⇒ “2.2 Engine-Subframe Mount Adjustment, Checking”, page
19 .
– Install the engine cover. Refer to
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
Tightening Specification

♦ Refer to
page 290
3.6 Subframe Mount, Adjusting

Procedure
WARNING
For all repair work, especially in the engine compartment due

to the tight working conditions, observe the following:
♦ Route all wires and lines so that the original path is fol‐
lowed.
or hot components.

⇒ “3.5 Engine, Supporting in Installation Position”, page 31 .
ProCarManuals.com
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– Loosen the bolts on the engine side and transmission side of

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– Tighten the subframe mount bolts.
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• Do not interchange the supply and return lines (return lines are
blue or have blue markings, supply lines are black). rrectness of i
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– Observe the safety precautions after connecting the Battery -

A- . Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Battery, Disconnecting and Connecting .
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3.7 Subframe Mount, Checking Adjustment

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• There must be a distance -a- of 10 to 13 mm between the

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Note
Distance -a- can also be checked with corresponding round stock.
If There Is Noise (the Engine or Transmission Hitting the Longi‐

tudinal Member When Driving around Curves). Refer to
If the Dimension -a- Is Not within 10 to 13 mm. Refer to

4 Special Tools
Special tools and workshop

equipment required
♦ Engine Support Bridge -
10-222A-
Engine Support 3 -
10-222A/3-
Gearbox Adapter -
10-222A/13-
Engine Support 18 -
10-222A/18-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Hose Clip Pliers -
VAS6362-
ProCarManuals.com
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4. Special Tools 37
4-Cylinder Diesel Engine (2.0L n AG. VolkCommon
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♦ Engine/Gearbox Support
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♦ Engine Support - Automatic
Transmission Hook -
t to the co
10-222A/7-
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Engine Support 28 -
10-222A/28-
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Engine Support 31 -
inform
10-222A/31-
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♦ Rail with Holes - T40091/2-

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i
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Basic Set - T40091-
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♦ Mount - T40093/5- from the
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Engine Support - Supple‐
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ment Kit - T40093A-
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Engine Support 28-2 -
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10-222A/28-2- , quantity: 2 Prote AG.
♦ Engine Support - Basic Set

- Square Pipe - T40091/1-
(quantity: 2) from the En‐
gine Support - Basic Set -
T40091-
♦ Engine Support - Basic Set
- Movable Joint - T40091/3-
(quantity: 2) from the En‐
gine Support - Basic Set -
T40091-
♦ Engine Support - Movable Joint - T40093/4- (quantity: 2) from the Engine Support - Supplement Kit -
T40093A-


♦ Hose Clamps - Up To
25mm - 3094- (vehicles
with manual transmission)
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Step Ladder - VAS5085-
AG. Volkswagen AG d
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4. Special Tools 39

♦ Engine and Gearbox
Bracket VAS6095A -
VAS6095A-
AG. Volkswagen AG d
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♦ Engine Support - Automatic Transmission Adapter - 10-222A/

16-
♦ Engine Bung Set - VAS6122-
♦ Engine And Transmission Holder - VAS6095-
♦ Wrench - Sw13 - T10384-
♦ Engine/Transmission Holder - Universal Mounting -
VAS6095/1-
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4. Special Tools 41
13 – Crankshaft, Cylinder Block

1 Engine, Disassembling and Assem‐Volkswagen A
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⇒ “1.1 Overview - Ribbed Belt Drive”, page 42 au ra
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⇒ “1.2 Overview - Toothed Belt Drive”, page 43
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⇒ “1.3 Overview - Cylinder Block”, page 46
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⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47
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⇒ “1.5 Ribbed Belt Tensioner, Removing and Installing”,
hole
page 49
spec
es, in part or in w
t to the co
⇒ “1.6 Sub-Assembly Bracket, Removing and Installing”,
page 50
⇒ “1.7 Engine Bracket, Removing and Installing”, page 52
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1.1 Overview - Ribbed Belt Drive
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1 - Belt Pulley/Vibration Damp‐

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❑ Only possible to install
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2 - Bolt
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3 - Generator - C-
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ling. Refer to ⇒ Electri‐
AG.
cal Equipment; Rep. Gr.

27 .
4 - Bracket
❑ For the sub-assembly
ling. Refer to
⇒ “1.6 Sub-Assembly
Bracket, Removing and
Installing”, page 50 .
5 - Bolt
❑ 20 Nm + 1/2 (180 °) ad‐
ditional turn
❑ Replace
❑ Do not lubricate or
grease the threads and
collar
❑ additional rotation can
occur in several stages
6 - Ribbed Belt Tensioner
❑ To release the tension
on ribbed belt, pivot us‐
ing a open end wrench.
Refer to
⇒ “1.4 Ribbed Belt, Re‐
moving and Installing”, page 47 .
42 Rep. Gr.13 - Crankshaft, Cylinder Block

7 - A/C Compressor
❑ Removing and installing. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 .
8 - Bolt
❑ 45 Nm
AG. Volkswagen AG d
9 - Alignment Sleeve agen oes
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10 - Ribbed Belt rise
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❑ Mark the runninga direction before removing
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❑ Check for wear
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❑ Do not kink
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❑ Removing and installing. Refer to ⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47 .
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1.2 Overview - Toothed Belt Drive
spec
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1 - Toothed Belt
❑ Mark the running direc‐
rrectness of i
tion before removing
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❑ Check for wear

❑ Do not kink
nform
ercia

ProCarManuals.com
ling, tensioning. Refer to

m
at
om
⇒ “1.6 Toothed Belt, Re‐
ion
c
moving, Installing and
in t
or
his
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Tensioning”, page 95 .
at
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2 - Bolt
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❑ 120 Nm + 1/4 (90 °) ad‐

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❑ Replace cop Vo
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❑ Use Counterhold - Prote AG.
Crankshaft Sprocket -
3415- when loosening
or tightening
❑ Do not lubricate or
grease the threads and
collar
❑ Additional rotation can
occur in several stages
3 - Crankshaft Toothed Belt
Sprocket
4 - Nut
❑ 20 Nm
5 - Idler Roller
6 - Nut
❑ 20 Nm + 1/8 (45 °) addi‐
tional turn
❑ Replace
7 - Tensioning Roller
❑ Remove the engine bracket to remove and install. Refer to
⇒ “1.7 Engine Bracket, Removing and Installing”, page 52 .
8 - Bolt
1. Engine, Disassembling and Assembling 43

olkswagen AG
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Golf Variant 2007Vo➤ lks,wGolf Variant 2010 ➤ , eJetta
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4-Cylinder Diesel
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❑ Replace aut or
ac
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9 - Camshaft Sprocket le
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10 - Bolt
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❑ 25 Nm
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11 - Bolt
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❑ 100 Nm
spec
es, in part or in w
12 - Hub
t to the co
❑ Use the Counterhold - Camshaft Gear - T10051- to loosen and tighten
❑ To remove, use Puller - Camshaft Sprocket - T10052- .
rrectness of i
❑ Removing and installing. Refer to ⇒ “2.2 Camshafts, Removing and Installing”, page 131 , Camshaft,
l purpos
Removing and Installing

13 - Rear Toothed Belt Guard
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14 - Bolt
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❑ 20 Nm
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15 - Bolt
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❑ 10 Nm
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❑ Replace
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16 - Idler Roller
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ProCarManuals.com
17 - Bolt co Vo
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❑ 50 Nm + 1/4 (90°) additional turn Prote AG.
❑ Replace
18 - Hub
❑ Use the Counterhold - Camshaft Gear - T10051- to loosen and tighten
❑ Use Puller - Pulley - T40039- to remove.
❑ Removing and installing. Refer to
⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”, page 325 .
19 - Nut
❑ 95 Nm
20 - High Pressure Fuel Pump Toothed Belt Sprocket
21 - Bolt
❑ Replace
22 - Coolant Pump
❑ Removing and installing. Refer to ⇒ “1.6 Coolant Pump, Removing and Installing”, page 203 .
23 - Bolt
❑ 15 Nm
24 - Toothed Belt Guard Upper Section
❑ Installing. Refer to ⇒ Fig. ““Toothed Belt Guard Upper Section, Installing”“ , page 45 .
25 - Toothed Belt Guard Lower Section
26 - Toothed Belt Guard Center Section
27 - Bolt
❑ 10 Nm
❑ Replace
28 - Bolt

❑ Replace
29 - Belt Pulley/Vibration Damper
❑ Only possible to install in one position - hole are offset
AG. Volkswagen AG d
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30 - Bolt Volksw
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❑ 5 Nm rise
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31 - Protective Plate ss au ra
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32 - Bolt un
pt
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❑ Replace
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❑ Note the tightening sequence. Refer to
h re
⇒ Fig. ““Engine Bracket to Cylinder Block Tightening Sequence”“ , page 19 .
ole,
spec
33 - Engine Bracket
t to the co
❑ Removing and installing. Refer to ⇒ “1.7 Engine Bracket, Removing and Installing”, page 52 .
rrectne
Toothed Belt Guard Upper Section, Installing
ss
– Make sure the toothed belt guard upper section is clipped into
o
cial p
f
the cylinder head cover correctly.
inform
mer
atio
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ProCarManuals.com
Note
o
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The camshaft is removed here for clarity.
iva
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– Press the toothed belt guard upper section near the clips
t.
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-arrows- against the cylinder head cover until the clips engage C py
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with each other. Use a screwdriver to press the guard if nec‐ gh ht
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– Check the clearance between the hub and the toothed belt
guard upper section.

1.3 Overview - Cylinder Block
1 - Cylinder Block
❑ Sealing flanges and fly‐
wheel, removing and in‐
stalling. Refer to
⇒ “2 Sealing Flange and
Flywheel”, page 55 .
❑ Piston and connecting
rod. Refer to
⇒ “3 Pistons and Con‐
necting Rod”,
page 68 .
❑ Crankshaft. Refer to
⇒ “4 Crankshaft”,
page 74 .
❑ Engine code CBEA with
balance shaft assembly
❑ Balance Shaft Assem‐
bly, Removing and in‐
stalling. Refer to
⇒ “2 Lubrication System
Components, Engine
Code CBEA”,
ProCarManuals.com
page 153 .
2 - Seal
❑ Replace
3 - Oil Filter Bracket
❑ Overview - Oil Filter
Bracket and Oil Cooler.
Refer to
⇒ “4.1 Overview - Oil Fil‐
ter Bracket and Oil Cool‐
er”, page 177 . AG. Volkswagen AG d
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❑ 15 Nm + 1/4 (90 °) addi‐ horis nte
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tional turn ss a ra
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❑ Replace
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❑ First, fasten upper left and lower right bolts, and then tighten all four bolts in a diagonal sequence
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5 - Bracket
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❑ For wiring harness

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6 - Bolt
spec
es, in part or in w
❑ 10 Nm
t to the co
7 - Connection
❑ For the coolant thermostat
rrectness of i
8 - Bolt
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❑ 15 Nm
9 - O-Ring
nform
ercia
❑ Replace
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at
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10 - Coolant Thermostat
n
c
in t
or
his
❑ Note the installation position. Refer to

ate
do
riv
⇒ “1.7 Coolant Thermostat, Removing and Installing”, page 204 , Coolant Thermostat, Removing and
p
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Installing
for
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❑ Checking: warm the thermostat in a water bath
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Rep. Gr.13 - Crankshaft, Cylinder Block Prote AG.
❑ Starts to open: approximately 85 °C (185 °F)
❑ Ends approximately 105 °C (221 °F)
❑ Opening lift minimum 7 mm
❑ Coolant thermostat, removing and installing. Refer to
⇒ “1.7 Coolant Thermostat, Removing and Installing”, page 204 .
❑ 4/2-Way Valve with Thermostat, Removing and installing. Refer to
⇒ “1.8 4/2-Way Valve with Coolant Thermostat, Removing and Installing”, page 205 .
11 - Bolt
❑ Replace
❑ Do not lubricate or grease the threads and collar
❑ additional rotation can occur in several stages
12 - Bracket
❑ For the sub-assembly
❑ Removing and installing. Refer to ⇒ “1.6 Sub-Assembly Bracket, Removing and Installing”, page 50 .
13 - Bolt
❑ Replace
14 - Ribbed Belt Tensioner
ProCarManuals.com
❑ To release the tension on ribbed belt, pivot using a open end wrench. Refer to
⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47 .
❑ Removing and installing. Refer to ⇒ “1.5 Ribbed Belt Tensioner, Removing and Installing”, page 49 .
15 - Oil Pan
❑ Clean sealing surface before installing
❑ Install with Silicone Sealant - D 176 404 A2-
16 - Bolt
❑ 15 Nm
❑ Tighten diagonally in steps
AG. Volkswagen AG d
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1.4 Ribbed Belt, Removing and Installing r nte
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⇒ “1.4.1 Removing”, page 47 .
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⇒ “1.4.2 Installing”, page 48 .

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Caution
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If large quantities of metal shavings or abrasions are detected

during engine repairs, it may mean the crankshaft or connect‐
ing rod bearings are damaged. To prevent further damage,
rrectness of i
perform the following steps after the repair:

l purpos
♦ Clean the oil channels carefully

♦ Replace the oil spray jets
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♦ Replace the oil cooler

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♦ Replace the oil filter.

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AG.
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– Mark the ribbed belt running direction.
– Move the tensioner in the direction of the -arrow- to release
the tension on the ribbed belt.
– Align the holes -arrows- to the cover and secure the tensioner
with the Locking Pin - T10060A- .
– Remove the ribbed belt.
ProCarManuals.com
1.4.2 Installing
Install in reverse order of removal. Note the. Vfollowing:
gen AG
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• Note the previouslyss marked direction of belt rotation and make
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sure that it is seated correctly on pulley.
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– Install the ribbed belt on the ribbed belt pulley.

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3- Generator
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4- A/C Compressor
After the belt is installed, always perform the following:
rrectness of i
– Start the engine and check the running belt.

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1.5 Ribbed Belt Tensioner, Removing and

Installing
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♦ Clean the oil channels
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♦ Replace the oil spray
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– Remove the ribbed belt. Refer to
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– Loosen the clamp -2-, lift the clip -1- and remove the connect‐
rrectness of i
ing hose »cold side«.
– Remove the air shroud with the Radiator Fan - V7- and Radi‐
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ator Fan 2 - V177- . Refer to

⇒ “1.4 Air Shroud with Radiator Fan V7 and Radiator Fan 2
nform
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V177 , Removing and Installing”, page 202 .

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– Open the clamp -2-, free up the coolant hose -3- and remove
the charge air pipe.
– Remove the bolt -2- and remove the ribbed belt tensioner
-1-. AG. Volkswagen
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♦ Replace the screw for the tensioner.ss
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♦ Tightening specifications. Refer to
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⇒ “1.1 Overview - Ribbed Belt Drive”, page 42 .
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1.6 Sub-Assembly Bracket, Removing and
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– Remove the engine bracket. Refer to

– Remove the high pressure pump. Refer to
⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”,
page 325 .
– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 .

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

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– Remove the A/C compressor from the sub-assembly
rised bracket ara
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and secure it to the lock carrier. ut
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– Remove the idler rollers -1 and 2- and remove the bolt on the
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– Remove the bolts -6 to 1- and remove the sub-assembly
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bracket.
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♦ Make sure there are alignment sleeves inside the sub-assem‐
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♦ Replace bolts, which have been tightened to torque.
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– Tighten the bolts in sequence -1 to 6-. Tightening specification

-item 5- ⇒ Item 5 (page 42) .
– Install the generator. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 .
– Install the high pressure pump. Refer to
page 325 .
– Install the engine bracket. Refer to

1.7 Engine Bracket, Removing and Instal‐

ling
Caution

Removing
WARNING

space.
♦ Route lines of all types (for example for fuel, hydraulic,
EVAP canister system, coolant and refrigerant, brake flu‐
id, vacuum) and electrical wiring so that the original path
is followed.
ProCarManuals.com

or hot components.
There is a risk of breaking for work on or near the vehicle align‐
ment.

– Remove the intake hose between the Mass Airflow geSensor
n AG. Volk-swagen AG do
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– Remove the filler neck from the windshield
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ut and headlamp or
ac
washer fluid reservoir. Refer to ⇒ Electrical Equipment; Rep.
s
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Gr. 92 ; Windshield Washer System; Washer Fluid Reservoir,

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Removing and Installing .

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– Remove the coolant expansion tank from the body (the coolant
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– Remove the fuel filter (the fuel lines remain connected).

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

es, in part or in w
t to the co
Exterior; Rep. Gr. 66 ; Wheel Housing Liner .

All Vehicles Except for Jetta from MY 2011.
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52
Prote AG.
Rep. Gr.13 - Crankshaft, Cylinder Block
Jetta from MY 2011

⇒ “3.5 Engine, Supporting in Installation Position”, page 31 .
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Continuation for All Vehicles
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♦ The subframe mount bolts may only be loosened when the atio
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engine is supported with the Engine Support Bridge -
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1. Bolts -3-
2. Bolts -1 and 2-
3. Bolts -4-
– Remove the engine mount -5-.
WARNING
Make sure that no components/hoses are damaged, stretched

or torn when lifting or lowering the engine using the Engine
Support Bridge - 10-222A- .
Note
The bolt -1- can be reached through an opening in the wheel

housing. If necessary, raise and lower the engine with the spindle
on the Engine Support Bridge - 10-222A- to remove or install the
bolts -2- and -3-.
– Remove the engine bracket bolts in the sequence -3 to 1-.

– Remove the engine bracket upward.

Installing
Caution
Always use the correct tightening sequence and specifications

for the engine bracket bolts. Otherwise tension could develop
in the engine bracket and break it.
• Subframe mount tightening specifications. Refer to

⇒ “2 Subframe Mount, except Jetta from MY 2011”, page 17 .
• Subframe mount tightening specifications. Refer to
⇒ “3 Assembly Mounts, Jetta from 2011”, page 23 .
– Install the engine bracket from above.
Note
The bolt -1- can be reached through an opening in the wheel

housing. If necessary, lift or lower the engine with the spindle for
the Engine Support Bridge - 10-222A- to remove wage
or. Vinstall
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3. Using the spindle, bring the engine bracket into position on

the engine mount -5-.
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1. Tighten the bolts -4-.

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– Checking the engine-subframe mount adjustment, except Jet‐

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⇒ “2.2 Engine-Subframe Mount Adjustment, Checking”, page

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⇒ “3.7 Subframe Mount, Checking Adjustment”, page 36 .

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• Do not interchange the supply and return lines (return lines are
blue or have blue markings, supply lines are black).

4-Cylinder Diesel Engine (2.0L Engine,
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⇒ “2.1 Overview - Sealing Flange and Flywheel”,
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⇒ “2.2 Crankshaft Sealing Flange, Removing and Installing”, page
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⇒ “2.3 Crankshaft Seal, Replacing, Belt Pulley Side”, page 63
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⇒ “2.4 Sealing Flange, Removing and Installing, Belt Pulley Side”,
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page 64
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⇒ “2.5 Engine Speed Sensor G28 , Removing and Installing”,
page 66
2.1 Overview - Sealing Flange and Flywheel
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♦ Vehicles with DSG® transmission. Refer to ⇒ 6-Speed Dual
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1 - Seal
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move oil residue from Prote AG.
crankshaft journal with a
clean cloth
❑ Seal for crankshaft - belt
pulley side- replacing.
Refer to
⇒ “2.3 Crankshaft Seal,
Replacing, Belt Pulley
Side”, page 63 .
2 - Sealing Flange
❑ Must rest on the align‐
ment sleeves
ling. Refer to
⇒ “2.4 Sealing Flange,
ling, Belt Pulley Side”,
page 64 .
❑ Insert with Silicone
Sealant - D 176 404
A2- . Refer to
⇒ “2.4 Sealing Flange,
ling, Belt Pulley Side”,
page 64 .
3 - Cylinder Block
❑ Piston and connecting
rod. Refer to
⇒ “3 Pistons and Con‐
necting Rod”,
page 68 .
❑ Crankshaft. Refer to
⇒ “4 Crankshaft”, page 74 .
❑ Engine code CBEA with balance shaft assembly
2. Sealing Flange and Flywheel 55

❑ Balance Shaft Assembly, Removing and installing. Refer to
⇒ “2 Lubrication System Components, Engine Code CBEA”, page 153 .
4 - Bolt
❑ Replace
5 - Flywheel
❑ To loosen and tighten the bolts, secure the flywheel G
with
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8 - Sealing Flange with Seal
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❑ Do not coat the sealing lip on the seal with oil or grease
t to the co
❑ Before installing, remove oil residue from crankshaft journal with a clean cloth
❑ Use the support sleeve provided to install
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ProCarManuals.com
⇒ “2.2 Crankshaft Sealing Flange, Removing and Installing”, page 56 .

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9 - Engine Speed Sensor - G28-
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❑ 5 Nm
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⇒ “2.5 Engine Speed Sensor G28 , Removing and Installing”, page 66 .
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2.2 Crankshaft Sealing Flange, Removing
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⇒ , page 57 Prote AG.
Removing:
♦ Seal Installer - Rear Crankshaft - T10134-
♦ Open Ring Wrench - 24mm - VAG1332/11-
♦ Caliper gauge
♦ M6 x 35 mm hex bolts (quantity: 3)
– Remove the transmission:
ual Transmission 02Q; Rep. Gr. 34 ; Transmission, Removing
and Installing .
♦ Vehicles with DSG® transmission. Refer to ⇒ 6-Speed DSG
Transmission 02E; Rep. Gr. 34 ; Transmission, Removing and
Installing .
– Remove the flywheel -item 5- ⇒ Item 5 (page 56) .
– Remove the intermediate plate -item 6- ⇒ Item 6 (page 56) .

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4-Cylinder Diesel
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– Turn the crankshaft to cylinder 1 TDC as shown.
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– Remove the oil pan:
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⇒ “2 Lubrication System Components, Engine Code CBEA”,
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page 153
spec
Engine Codes CJAA. Refer to
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⇒ “3 Lubrication System Components, Engine Code CJAA”,
page 170 .
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Note
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♦ To improve clarity, the work procedures will be shown with the
nform
engine removed.
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♦ The work procedures are the same with the engine installed
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and the transmission removed.
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– Remove the Engine Speed Sensor - G28- . Refer to

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page 66 .
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– Remove the sealing flange bolts.
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ProCarManuals.com
Note
The sealing flange and sensor wheel are pressed together off the
crankshaft with three M6 x 35 mm bolts.
– Install the three M6 x 35 mm bolts in the threaded holes on the

sealing flange -arrows-.
– Screw the bolts (max. one 1/2 turn (180°) per bolt) into the
sealing flange in an alternating sequence and press the seal‐
ing flange together with the sensor wheel off the crankshaft.
Installing:
Note
♦ Sealing flange with PTFE-seal is equipped with a sealing lip

support ring. This support ring serves the same function of a
guide sleeve and must not be removed before installation.
♦ The sealing flange and sensor wheel must not be separated
or rotated after being removed from the replacement part
packaging.
♦ The sensor wheel retains the installation position via being lo‐
cated on the locating pin of the Seal Installer - Rear Crankshaft
- T10134- .
♦ The sealing flange and seal are one unit and may only be re‐
placed together with the sensor wheel.
♦ The Seal Installer - Rear Crankshaft - T10134- retains the in‐
stallation position to the crankshaft via a guide pin, which is
guided into the hole of the crankshaft.

Seal Installer - Rear Crankshaft - T10134-

A - Tension Surface
B - Hex Nut
C - Assembly Bell
D - Locating Pin
E - Hex Socket Bolt
F - Guide Pin for Diesel Engines (Black Handle)
G - Guide Pin for Gasoline Engines (Red Handle)
A - Installing the Gasket with Sensor Wheel on the Seal Installer
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– Screw on the nut -B- until shortly before the tension surfacehoris tee
-A- of the threaded spindle. aut or
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– Tension the Seal Installer - Rear Crankshaft - T10134- in a
ce
le
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vise on the tension surface -A- of the threaded spindle.
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– Push the assembly bell -C- downward so that it rests on the
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ProCarManuals.com
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– Install the hex nut on the threaded spindle until the inner sec‐
tion of the assembly tool is level with the assembly bell.
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– Remove the securing clip -arrow- from the new sealing flange. Prote AG.
Note
The sensor wheel must not be removed from or rotated in the

sealing flange.

– The locating pin -A- on the sensor wheel -C- must align with
the marking -B- on the sealing flange.
– Place the front side of the sealing flange onto a clean level
surface. wage
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– Press the sealing lip support ring -A- in the direction of
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-arrow- until it rests on the level surface.
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– The upper edge of the sensor wheel and the front edge of the do
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– Place the front side of the sealing flange on the Seal Installer
- Rear Crankshaft - T10134- so the locating pin -B- is posi‐
tioned in the hole -A- on the sensor wheel.
Note
Make sure the sealing flange is positioned flat on the seal installer.

– Press the sealing flange and the sealing lip support ring -B-
onto the surface of the Seal Installer - Rear Crankshaft -
T10134- while tightening the three knurled bolts -A- so that the
locating pin cannot slip out of the sensor wheel hole.
Note
Make sure the sensor wheel remains fixed inside the assembly
tool when installing the sealing flange. . Volkswag
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– Push the threaded spindle on the Seal Installer - Rear Crank‐
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shaft - T10134- in the direction of -arrow- until the hex nut
-B- rests on the assembly bell -A-.
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ProCarManuals.com
– Position the flattened side of the assembly bell toward the oil
pan side of the cylinder block sealing surface.
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Screw the hex socket bolts -A- approximately five threads into the
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crankshaft flange using the hex socket bolts -A-.

– Screw two M7 x 35 mm bolts -A- to guide the sealing flange

into the cylinder block.
C - Attaching the Seal Installer - Rear Crankshaft - T10134- to the
Crankshaft Flange
– Push the assembly bell -C- by hand in the direction of
-arrow- until the sealing lip support ring -B- rests on the crank‐
shaft flange -A-.
– Push the guide pin for diesel engines (black handle) -D- into
the crankshaft hole. Thereby the sensor wheel is retained in
the final installation position.
Note
Do not insert the guide pin for gasoline engines (red handle) -F-
into the crankshaft threaded hole.
– Hand-tighten both hex socket bolts on the Seal Installer - Rear

Crankshaft .
– Install the nut -E- onto the threaded spindle by hand, until it
rests on the assembly bell -C-.
D - Installing the Sensor Wheel on the Crankshaft Flange with the
Seal Installer - Rear Crankshaft - T10134- .
ProCarManuals.com
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– Tighten the hex nut ondthe by Seal Installer - Rear Crankshaft
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T10134- using a Torque
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Wrench 5-50Nm - VAG1331- and nte
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After tightening the hex nut to 35 Nm, a minimal air gap must still
spec
be present between the cylinder block and sealing flange.

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E - Checking the Sensor Wheel Installation Position on the Crank‐

shaft
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– Screw the hex nut -E- to the end of the threaded spindle.
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– Remove the two bolts -A- from the cylinder block.

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– Remove the three knurled bolts -B- from the sealing flange.
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– Remove the Seal Installer - Rear Crankshaft - T10134- .

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– Remove the sealing lip support ring.
The installed position of the sensor wheel on the crankshaft is

exact, if a gap -a- of 0.5 mm is present between the crankshaft
flange -A- and sensor wheel -B-.
ProCarManuals.com
AG. Volkswagen AG d
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– Set a caliper gauge onto the crankshaftby
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– Measure the gap -a- betweenut
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– Press the sensor wheel again. Refer to ⇒ page 62 .

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If dimension -a- is obtained:

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– Tighten the new sealing flange bolts alternating in a diagonal

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• Tightening specification -item 7- ⇒ Item 7 (page 56) .

– Install the Engine Speed Sensor - G28- . Refer to
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page 66 .
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– Install the oil pan:

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page 153
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– Install the intermediate plate -item 6- ⇒ Item 6 (page 56) .

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– Install the flywheel with new bolts: t. C rig
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F - Pressing in the Sensor Wheel
– Secure the Seal Installer - Rear Crankshaft - T10134- onto the
crankshaft flange using the hex socket bolts -A-.
– Hand-tighten both hex socket bolts -A-.

– Push the Seal Installer - Rear Crankshaft - T10134- onto the

sealing flange by hand.
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– Install the nut -E- onto the threaded spindle by hand, until it
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– Tighten the hex nut on the Seal Installer - Rear Crankshaft -
com
tio
T10134- using a Torque Wrench 5-50Nm - VAG1331- and
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Torque Wrench 1332 Insert - Open Ring Wrench - 24mm -

te o
thi
VAG1332/11- .
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– Check the installed position of the sensor wheel on the crank‐ Cop py
. rig
shaft again. Refer to ⇒ page 61 .
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rig by
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If dimension -a- is too small:
by lksw
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Prote AG.
– Tighten the nut on the Seal Installer - Rear Crankshaft -
T10134- :
– Check the installed position of the sensor wheel on the crank‐
shaft again. Refer to ⇒ page 61 .
2.3 Crankshaft Seal, Replacing, Belt Pulley

Side
Removing:
♦ Puller - Crankshaft Seal - 3203-
♦ Counterhold - Crankshaft Sprocket - 3415-
♦ Seal Installer - Crankshaft Seal - T10053-
– Remove the toothed belt. Refer to
⇒ “1.6 Toothed Belt, Removing, Installing and Tensioning”,
page 95 .

– Remove the crankshaft toothed belt sprocket. Secure the

toothed belt sprocket with the Counterhold - Crankshaft
Sprocket - 3415- .
– To guide the Puller - Crankshaft Seal - 3203- , install the center
bolt by hand into the crankshaft all the way.
– Turn the inner section of the Puller - Crankshaft Seal - 3203-
two turns (approximately 3 mm) out from the outer section and
lock it with the knurled bolt.
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– Lubricate the threaded head on the Pullerks-wCrankshaft
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– Install the seal puller as far as upossible
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– Loosen the knurled bolt and turn the inner section against the
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crankshaft until the seal is pulled out.
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Installing:
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The sealing lip of the seal may not be additionally oiled or
greased.
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– Wipe off any oil that may still be on the end of the crankshaft
ProCarManuals.com
with a clean cloth.
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– Place Seal Installer - Crankshaft Seal - Guide Sleeve -
f in
T10053/1- on the crankshaft journal.
form
mer
atio
– Push the seal over the Guide Sleeve onto the crankshaft jour‐
om
nal.
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Cop py
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– Press the seal in all the way with the Seal Installer - Crankshaft
Seal - T10053- and the center bolt.
– Install the crankshaft toothed belt sprocket:
– Installing and tensioning the toothed belt. Refer to
page 95 .
2.4 Sealing Flange, Removing and Instal‐

ling, Belt Pulley Side
Removing
♦ Counterhold - Crankshaft Sprocket - 3415-
♦ Seal Installer - Crankshaft Seal - T10053-


♦ Not illustrated
♦ Hand Drill with Plastic Brush Attachment
♦ Protective Eyewear
♦ Flat-Blade Scraper
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♦ Silicone Sealant - D 176
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– Remove the toothed
orise belt. Refer to nte
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page 95 . ss c
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un
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– Remove the crankshaft toothed belt sprocket. Secure the
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toothed belt sprocket with the Counterhold - Crankshaft
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Sprocket - 3415- .
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– Remove the oil pan:
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spec
t to the co
page 153
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page 170 .
ProCarManuals.com
– Remove the sealing flange belt pulley side.
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– Remove the sealing flange. If necessary, loosen it by tapping
inform
lightly with a rubber mallet.
mer
atio
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– Remove the sealant residue from cylinder block with a flat-

o
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c
blade scraper.
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Wear protective eyewear. Cop py
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– Remove sealant residue from sealing flange using a rotating
plastic brush (wear safety glasses).
– Clean the sealing surfaces. They must be free of oil and
grease.
Installing:
Note
♦ Note the expiration date for the Sealant .

♦ The sealing flange must be installed within five minutes after
applying the Silicone Sealant .

– Cut the tube nozzle at front marking (nozzle diameter: approx‐

imately 3 mm).
Note
♦ The sealant bead must not be thicker than 2 to 3 mm.

♦ Otherwise the extra sealant will get into the oil pan and can
block the screen in the oil pump suction line.
♦ The sealant also must not drip onto the crankshaft seal sealing
surface.
♦ Before applying the bead of sealant, cover the sealing surface
on the seal with a clean cloth
– Apply a silicone sealant bead to the sealing surface of the

sealing flange as shown.
– Install the sealing flange immediately and tighten all bolts light‐
ly.
Note
Use Seal Installer - Crankshaft Seal - T10053/1- to position the

ProCarManuals.com
sealing flange on the installed seal.
– Tighten the sealing flange bolts in a diagonal sequence:

– Install the crankshaft toothed belt sprocket:
AG. Volkswagen AG d
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• Tightening specification -item 2- ⇒VItem
olks 2 (page 43) .
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– Install the oil pan: oris nte
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Engine Code CBEA. Refer
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page 153
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page 170 .
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Note
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After assembly, allow the Sealant to dry for approximately 30 mi‐

nutes. Only afterward may the engine oil be replenished.
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page 95 .
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2.5 Engine Speed Sensor - G28- , Remov‐

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Removing:
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Cop py
. rig
♦ Hose Clamps - Up To 25 mm - 3094-
t
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Conditions
Procedure
– Clamp off the coolant hoses from the oil cooler using Hose
Clamps - Up To 25mm - 3094- .
– Loosen the spring clamps -arrows- using the Hose Clip Pliers
- VAS6362- .
Note
Catch leaking coolant with the Drip Tray - VAS6208- .
– Disconnect the coolant hoses from the oil cooler.

– Remove the oil filter bracket. Refer to
⇒ “4.1 Overview - Oil Filter Bracket and Oil Cooler”,
page 177 .
– Remove the bolt -arrow- and the Engine Speed Sensor - G28- .
ProCarManuals.com
Installing:
• Engine Speed Sensor - G28- tightening specification -item 9-
⇒ Item 9 (page 56) .
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• Oil filter bracket tightening specifications. Refer lto ksw
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page 177 , Overview - Oil filter Bracket andris Oil Cooler
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– Check the coolant level and fill if necessary.
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3 Pistons and Connecting Rod

⇒ “3.1 Overview - Piston and Connecting Rod”, page 68
⇒ “3.2 New Connecting Rod, Separating”, page 71
⇒ “3.3 Bearing Shells - Installation Position”, page 72
⇒ “3.4 Piston and Cylinder Dimensions”, page 72
. Volkswagen AG
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⇒ “3.5 Piston Projection
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1 - Piston Rings
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❑ Offset gaps by 120°
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❑ “TOP” identification
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crown
❑ Checking the ring gap.
Refer to
rrectness of i
⇒ Fig. ““Checking the
ProCarManuals.com
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Piston Ring Gap”“ ,

page 69 .
❑ Checking the groove
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clearance. Refer to
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⇒ Fig. ““Piston Ring

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❑ With the internal com‐

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Cop py
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❑ Mark the installed posi‐
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tion and cylinder alloca‐
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❑ Installed position and al‐

location, piston/cylin‐
der. Refer to
⇒ Fig. ““Installed Posi‐
tion of Piston and Pis‐
ton/Cylinder Alloca‐
tion”“ , page 71 .
❑ Arrow on piston crown
points toward belt pulley
side
❑ Install with piston ring
compressor
❑ Replace the piston if the
piston shaft is cracked
❑ Check the piston projection in TDC. Refer to
⇒ “3.5 Piston Projection in Top Dead Center (TDC), Checking”, page 72 .
3 - Piston Pin
❑ If difficult to move, heat piston to 60 °C (140 °F)
❑ Remove and install using the Pilot Drift - VW222A-
4 - Circlip
5 - Connecting Rod
❑ Label the allocation to the cylinder using a color marker -A-

❑ Installation position: the marks -B- face the belt pulley side
❑ With cracked bearing cap
❑ New connecting rod, disconnecting. Refer to ⇒ “3.2 New Connecting Rod, Separating”, page 71 .
6 - Bearing Shell
❑ Note the installation position Refer to ⇒ “3.3 Bearing Shells - Installation Position”, page 72 .
❑ Pay attention to the version: upper bearing shell (facing the piston) is made from wear resistant material;
characteristic: a black line on the running surface near the separating point
❑ Do not interchange used bearing shells.
❑ Insert bearing shells in the center
❑ Check for secure fit
❑ Axial play wear limit: 0.37 mm
❑ Measure the radial play with Plastigage®: wear limit: 0.08 mm
❑ Do not turn the crankshaft when measuring radial clearance
7 - Cylinder Block
❑ Checking the cylinder bore. Refer to ⇒ Fig. ““Cylinder Bore, Checking”“ , page 70 .
❑ Pistons and cylinder dimensions. Refer to ⇒ “3.4 Piston and Cylinder Dimensions”, page 72 .
8 - Connecting Rod Bearing Cap
❑ Note the installation position
❑ Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only
fits in one position and only to the corresponding connecting rod.
ProCarManuals.com
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9 - Oil Spray Jet wage
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10 - Bolt with Pressure
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❑ Install without sealant

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11 - Connecting Rod Bolt

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❑ 30 Nm + 1/4 (90°) additional turn

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❑ Replace
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spec
❑ Lubricate the threads and contact surface.

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t to the co
❑ Use the old bolt to measure the radial clearance

rrectness of i
Checking the Piston Ring Gap

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♦ Feeler Gauge
Procedure
– Push the piston ring squarely from above down to approxi‐
mately 15 mm from edge of the cylinder.
3. Pistons and Connecting Rod 69

Piston Ring Ring Gap

Dimensions in mm New Wear limit
1. Compression ring 0.20 to 0.40 1.0
Oil Scraping Ring 0.25 to 0.50 1.0
Piston Ring Groove Clearance, Checking

♦ Feeler Gauge
ProCarManuals.com
Procedure
– Clean the ring groove before checking.
Piston Ring Ring to Groove Clearance
Dimensions in mm New Wear limit
2. Compression ring 0.05
ksw to 0.08
age es n 0.25
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Oil Scraping Ring d by 0.03 to 0.06 ua
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Cylinder Bore, Checking

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Cop py
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♦ Inner measuring device 50 to 100 mm
rig
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Procedure
– Measure bores at three locations diagonally transversely -A-
and lengthwise -B- in line with crankshaft.
• Deviations to the specified size: maximum 0.10 mm
Note
The cylinder bore must not be measured when the cylinder block
is mounted in the Engine and Gearbox Bracket - VAS6095A- be‐
cause the measurements may be incorrect.
Installed Position of Piston and Piston/Cylinder Allocation

The arrow on the piston crown -arrows- points toward the belt swa
gen AG
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3.2 New Connecting Rod, Separating
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New connecting rods might not be completely separated at the
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predetermined breaking point. If it is difficult to remove the con‐
ility
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necting rod bearing cap by hand, do the following:
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– Mark which cylinder belongs to the connecting rod.
hole
ProCarManuals.com
spec
es, in part or in w
– To prevent damage, only clamp the connecting rod lightly in a
t to the co
vise with protective covers over the jaws as shown.
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Note
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Clamp the connecting rod below the dotted line.
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– Remove the bolts -arrows- approximately five turns.
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Cop py
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– Carefully tap the connecting rod bearing cap with a plastic

hammer in direction of -arrow- until it comes loose.

3.3 Bearing Shells - Installation Position

Bearing shell -1- with connecting rod oil filler hole -arrow-.
Bearing shell -2- without oil filler hole for connecting rod cover.
– 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.
AG. Volkswagen AG d
agen oes
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3.4 Piston and Cylinder Dimensions d ara
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Honing dimension ss
Piston and Cylinder Dimensions
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Dimensions in mm Cylinder bore diameter
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Piston diameter 1)
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Standard dimension 80.960 81.010
erm
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1) Take measurement approximately 12 mm from the lower edge
wit
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of the piston and offset 90° to the piston pin axis.
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hole
spec
ProCarManuals.com
es, in part or in w
t to the co
3.5 Piston Projection in Top Dead Center
(TDC), Checking rrectness of i
⇒ “3.5.1 Cylinder Head Gasket Identification”, page 73

l purpos

nform
ercia
♦ Measuring Bar - VW382/7-

m
at
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-

om
ion
c
in t
r
♦ Dial Gauge - 0-10mm - VAS6079-

o
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ate
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Test Sequence
p
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When installing new pistons or working with a partial engine,

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ng
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check the piston projection in TDC on all pistons. Depending on Cop py
the piston projection, install the corresponding cylinder head gas‐
t. rig
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ket according to the following table. op Vo
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Prote AG.
Note
♦ To measure the piston position at TDC, turn the engine clock‐

wise.
♦ If varying values occur when measuring the projection, use the
gasket for the largest value.
Piston Projection Identification

Notches/Holes
Dimensions in mm
0.91 to 1.00 1
1.01 to 1.10 2
1.11 to 1.20 3

3.5.1 Cylinder Head Gasket Identification

♦ Part number = -arrow 1-
♦ Holes = -arrow 2-
♦ Control code = -arrow 3- (ignore this!)
AG. Volkswagen AG d
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♦ Depending on piston
aut projection, varying cylinder head gasket
h
ra
thicknesses cans be installed. Be sure to use a gasket having
s c
ce
le
the identical identification when replacing.

un
pt
an
d
itte
♦ Determine the piston position in TDC when installing new pis‐
y li
erm
ab
tons or partial engines. Refer to
ility
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⇒ “3.5 Piston Projection in Top Dead Center (TDC), Check‐
wit
is n
ing”, page 72 .
h re
ole,
spec
t to the co
rrectness
ProCarManuals.com
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Cop py
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Prote AG.

4 Crankshaft
⇒ “4.1 Overview - Crankshaft”, page 74
⇒ “4.2 Crankshaft Dimensions”, page 75
⇒ “4.3 Needle Bearings, Removing and Installing from Crank‐
shaft”, page 75
4.1 Overview - Crankshaft
Caution
♦ If the crankshaft is removed, a new intermediate sprocket

must
-item 14- ⇒ Item 14 (page 154) be installed with coating
and the hub -item 11- ⇒ Item 11 (page 154) including the
bolt -item 12- ⇒ Item 12 (page 154) and axial bearing
discs -item 13- ⇒ Item 13 (page 154) must be replaced,
or else the backlash will not be correct.
♦ Installation procedure. Refer to
⇒ “2.4.2 New Balance Shaft Assembly, Installing”,
page 161 , New Balance Shaft Assembly, Installing
ProCarManuals.com
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1 - Bearing Shells 1, 2, 4 and 5 d byV ua
ran
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❑ For bearing cap without tho tee
or
oil groove au ac
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❑ For cylinder block with
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oil groove
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❑ Do not interchange
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used bearing shells
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(mark them)
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2 - Bolts
spec
❑ 65 Nm + 1/4 (90 °) addi‐
es, in part or in w
tional turn t to the co

❑ Replace
rrectness of i
❑ Tighten to 65 Nm to
measure radial clear‐
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ance but do not tighten

further.
nform
ercia
3 - Bearing Cap
m
at
❑ Bearing cap 1: belt pul‐

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ion
ley side
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or
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❑ Bearing cap 3 with

at
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openings for thrust

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washers
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❑ Retaining tabs for cylin‐
Co
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bearing shells must lie pyri by
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above one another
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Prote AG.
4 - Bearing Shell 3
❑ For bearing cap without
oil groove
❑ For cylinder block with
oil groove
5 - Thrust Washer
❑ For the bearing cap 3

❑ Pay attention to the installation position
6 - Crankshaft
❑ “Pay attention to the warnings”. Refer to ⇒ page 74 .
❑ New axial play: 0.07 to 0.17; wear limit: 0.37 mm
❑ Measure the radial clearance with Plastigage®. New: 0.03 to 0.08 mm, wear limit: 0.17 mm
❑ Do not turn the crankshaft when measuring radial clearance
❑ Crankshaft dimensions. Refer to ⇒ “4.2 Crankshaft Dimensions”, page 75 .
7 - Thrust Washer
❑ For cylinder block, bearing 3
4.2 Crankshaft Dimensions

Dimension Crankshaft Bearing Connecting Rod Bearing
Pin Diameter Pin Diameter
Dimensions in mm
Standard dimension 54.000 -0.022 50.90 -0.022
-0.042 -0.042
4.3 Needle Bearings, Removing and Instal‐

ProCarManuals.com
ling from Crankshaft

Only Vehicles with a DSG® Transmission
♦ Puller - Kukko Internal - 14-19mm - 21/2-
♦ Puller - Kukko Counterstay - 22/1-
♦ Alignment Tool - Clutch Plate - 3176-
Volkswa
♦ Bearing Installer - Bearing PressswPiece
agen - VW207C- AG does
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Always replace the needle bearing -arrow- if the engine or the

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transmission is being removed.

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Procedure
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• The transmission is unflanged from the engine

hole
spec
Remove the needle bearing:

es, in part or in w
t to the co
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– Remove with a commercially available puller -A-, for example

Puller - Kukko Internal - 14-19mm - 21/2- and Puller - Kukko
l purpos
Counterstay - 22/1- .
Installing
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♦ -1- Puller - Kukko Internal -
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14-19mm - 21/2-
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spec
♦ -4- Puller - Kukko Counter‐
t to the co
stay - 22/1-
♦ Alignment Tool - Clutch
Plate - 3176-
rrectne
♦ Bearing Installer - Bearing
s
Press Piece - VW207C-
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5. Special Tools 77
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♦ Seal Installer - Rear Crank‐ yV
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♦ Torque Wrench 1331 au ac
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♦ Open Ring Wrench - 24mm
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♦ Puller - Crankshaft Seal -

3203-
♦ Counterhold - Crankshaft
Sprocket - 3415-
♦ Seal Installer - Crankshaft
Seal - T10053-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
ProCarManuals.com
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5. Special Tools
♦ Counterhold - Crankshaft
Sprocket - 3415-
♦ Seal Installer - Crankshaft
Seal - T10053-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
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♦ Hose Clamps - Up To 25
mm - 3094-
5-50Nm - VAG1331-
♦ Shop Crane - Drip Tray -
VAS6208-
VAS6362-
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♦ Locking Pin - T10060A-
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AG.
5. Special Tools
♦ Measuring Bar - VW382/7-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-

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♦ Not illustrated:
♦ Caliper gauge
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15 – Cylinder Head, Valvetrain

1 Cylinder Head
⇒ “1.1 Overview - Cylinder Head Cover”, page 83
⇒ “1.2 Overview - Cylinder Head”, page 85
⇒ “1.3 Camshaft Position Sensor G40 , Removing and Installing”,
page 87
⇒ “1.4 Engine Cover, Removing and Installing”, page 90
⇒ “1.5 Cylinder Head Cover, Removing and Installing”,
page 90
⇒ “1.6 Toothed Belt, Removing, Installing and Tensioning”, page
95
⇒ “1.7 Cylinder Head, Removing and Installing”, page 103
⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126
⇒ “1.9 Compression, Checking”,wapage
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3 - Protective Strip
spec
❑ For the rail element

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(high pressure reser‐

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lines
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4 - Rail Element (High Pres‐

sure Reservoir)
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7 - Nut
❑ 10 Nm
8 - Tensioning Claw
❑ Replace
❑ Note the installation po‐
sition Refer to
⇒ Fig. ““Tensioning
Bracket Installation Po‐
sition”“ , page 314 .
1. Cylinder Head 83
9 - Fuel Injector (Piezo Injector)

Overview - Fuel System. Refer to ⇒ “3.3 Overview - Fuel System”, page 311 .
AG. Volkswagen AG d
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13 - Seal
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❑ Replace if damaged or leaking
es, in part or in w
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14 - Bolts
❑ 10 Nm
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❑ Observe the sequence for loosening and tightening . Refer to
⇒ “1.5 Cylinder Head Cover, Removing and Installing”, page 90 , Cylinder Head Cover, Removing and
l purpos
Installing
15 - Cap
nf
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❑ Replace the seal if damaged.
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16 - Heat Shield
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17 - Bushing
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❑ For the rail element (high pressure reservoir) - mounting

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84 Rep. Gr.15 - Cylinder Head, Valvetrain

Golf Variant 2007 ➤ , Golf Variant
A 2010
G. Volkswagen A➤
G d,oJetta 2005 ➤ , Jetta 2011 ➤
agen
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❑ Observe the notes. Re‐
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❑ Checking for distortion.
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⇒ Fig. ““Cylinder Head,
es, in part or in w
Checking for Distor‐
t to the co
tion”“ , page 86 .
rrectness of i
ling. Refer to
⇒ “1.7 Cylinder Head,
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ling”, page 103 .
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❑ All of the coolant must
or
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3 - Cylinder Head Bolt
❑ Observe the sequence
for loosening and tight‐
ening . Refer to
⇒ “1.7 Cylinder Head,
ling”, page 103 , Cylin‐
der Head, Removing
and Installing
❑ Before installing, insert
washers -item 2-
⇒ Item 2 (page 85) into
cylinder head
4 - Bolt
❑ 25 Nm
5 - Lifting Eye
6 - Seal
❑ Replace
7 - Vacuum Pump
DANGER!
Do not disassemble the
vacuum pump under any
circumstances because
it can cause the vacuum
component to malfunc‐
tion. The result would be
brake booster failure.
❑ Removing and installing. Refer to ⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126 .
8 - Bolt
❑ 10 Nm
1. Cylinder Head 85
9 - Coolant Connection
❑ Coolant Hose Connection Diagram. Refer to ⇒ “1.3 Coolant Hose Connection Diagram”, page 197 .
10 - Bolt
❑ 10 Nm
11 - Seal
❑ Replace
12 - Bolt
❑ 25 Nm
13 - Lifting Eye
14 - Cylinder Head Gasket
❑ Replace
❑ Observe the identification. Refer to ⇒ Fig. ““Cylinder Head Gasket Identification”“ , page 87 .
❑ All of the coolant must be replaced after replacing
15 - Camshaft Position Sensor - G40-
❑ For camshaft position
16 - Bolt
❑ 10 Nm
ProCarManuals.com
Cylinder Head, Checking for Distortion
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♦ Straight Edge - 500mm - VAS6075-

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♦ Feeler Gauge
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Procedure
rrectness of i
– Check the cylinder head in several places for distortion using

a Straight Edge and a feeler gauge.
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• Maximum permitted distortion: 0.10 mm.

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Remanufacturing diesel cylinder heads is not permitted.
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♦ Holes = -arrow 2-
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♦ Control code = -arrow 3- (ignore this!)
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♦ Installed position: the identification mark faces up.
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♦ Depending on piston projection, varying cylinder head gasket
inform
thicknesses can be installed. When replacing a gasket, install
mer
a gasket with the same identification -arrow 3-.
atio
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n
♦ Determine the piston position at TDC when installing new pis‐
c
i
or
n
tons or a partial engine. Refer to
thi
te
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⇒ “3.5 Piston Projection in Top Dead Center (TDC), Check‐

iv
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– Remove the fuel filter and the Auxiliary Fuel Pump - V393- .
Refer to
– Disconnect the connector from the Engine Coolant Tempera‐
ture Sensor on Radiator Outlet - G83- .
– Open the clamps -arrows- and remove the toothed belt guard.
– Remove the right front wheel housing liner.
– Remove the vibration damper -item 29- ⇒ Item 29 (page 45) .
1. Cylinder Head 87
– Rotate the engine to TDC and secure the crankshaft toothed

belt sprocket with the Crankshaft Stop - T10050- . Push the
crankshaft stop from the front side of the toothed belt sprocket
into the splines. The camshaft toothed segment must be in the
»12 o'clock« position.
Note
The markings on the crankshaft toothed belt sprocket -2- and the
Crankshaft Stop - T10050- -1- must align. The pin on the Crank‐
shaft Stop - T10050- must engage in the hole on the sealing
flange.
– Loosen the camshaft sprocket bolts -1-.

ProCarManuals.com
– Loosen the coolant pipe bolt -1- and then the bolts for the high
pressure pump toothed belt sprocket -2-.
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– Loosen the tensioning roller nut -1- and turn the tensioning
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roller eccentric pulley with the Wrench - Tensioning Roller -

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T10264- counter-clockwise in direction of -arrow-, until the

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Locking Tool - T10265- .

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Rep. Gr.15 - Cylinder Head, Valvetrain
– Now turn the tensioning roller eccentric pulley clockwise in di‐

rection of -arrow- all the way and tighten the nut -1- by hand.
– Remove the toothed belt from the idler roller and the high
pressure pump.
– Disconnect the connector for the Camshaft Position Sensor -

G40- -arrow-. AG. Volkswagen AG d
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– Disconnect
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– Remove the Camshaft Position Sensor - G40- -arrow-.
– Remove the ribs with a screwdriver and remove the cover for
rrectness of i
the opening -arrows-.

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– Remove the Camshaft Position Sensor - G40- from the cylin‐
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♦ Seal the opening in the toothed belt guard with a rubber plug.
Refer to the Parts Catalog.
– Mount the toothed belt and adjust the valve timing. Refer to
⇒ , page 98 .
1. Cylinder Head 89
1.4 Engine Cover, Removing and Installing

Removal
– Pull the engine cover at the corners in direction of -arrows-
upward out of the mounting points with a jerking motion.
Installing
Caution
Make sure the four fasteners (ball sockets) are positioned cor‐
rectly before installing the engine cover. Move them back into
their position, if necessary. Otherwise the engine cover could
be damaged.
– Press the engine cover ball sockets into the correct
olks
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– Position the engine cover on the mounting
tho points and press or
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1.5 Cylinder Head Cover, Removing and In‐

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♦ When replacing the cylinder head or cylinder head gasket, all
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of the coolant must be replaced.
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♦ Cylinder heads with cracks between the valve seats can con‐
tinue to be used without reducing service life, as long as the
tears have a width of maximum 0.5 mm.
♦ After working on the valvetrain and engine, carefully rotate by
hand at least two full turns to be sure that valves do not strike
pistons when starting.
clamps.
♦ Overview - Cylinder Head Cover. Refer to
⇒ “1.1 Overview - Cylinder Head Cover”, page 83 .


♦ Union Nut Socket - T40055-

♦ Torque Wrench 1331 Insert - Reversible Ratchet -
VAG1331/1-
DANGER!

direct fuel injection system. Refer
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⇒ “1 Safety Precautions yV
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♦ Pay attention
sa
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ac
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s
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– Remove the engine cover. Refer to pyri by
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– Remove the protective strip -item 3- ⇒ Item 3 (page 83) .
– Disconnect from the fuel injectors -A-, the Exhaust Pressure
Sensor 2 - G451- -B- and the Fuel Pressure Sensor - G247-
-C-.
– Remove the coolant line bolts -arrows- from the intake mani‐
fold and lay the line in front of the intake manifold.
– Unclip the wiring harness from the wiring guide for the glow
plugs.
Caution
Always follow the procedure »Glow Plug Connectors, Remov‐

ing and Installing«.
– Remove the glow plug connectors. Refer to

⇒ “1.3 Glow Plug Connectors, Removing and Installing”, page
410 .
– Remove the fuel return line bolt -item 3-
⇒ Item 3 (page 312) on the intake manifold.
1. Cylinder Head 91
– Loosen the hose clip -arrow- with the Hose Clip Pliers -
VAS6362- and remove the line on the rail element (high pres‐
sure reservoir).
– Before removing, clean the return line connection on the fuel
injectors (for example using a commercially available deter‐
gent).
– Cover the return line connections with a cleaning cloth.
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– Remove the fuel return line connections on the fuel injectors.
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♦ Follow the rules of cleanliness.
hole
spec
♦ Do not let any dirt to get into the disconnected return lines or
es, in part or in w
t to the co
into the connections for the fuel injectors.
– Loosen the spring clamp with the Hose Clip Pliers - VAS6362-
rrectness of i
ProCarManuals.com
and remove the fuel return line -item 4-

⇒ Item 4 (page 312) .
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– Loosen the spring clamp -4- with the Hose Clip Pliers -
VAS6362- and disconnect the fuel return line at the high
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– Disconnect from the Charge Air Pressure Actuator Position

Sensor - G581- -arrow- at the turbocharger vacuum dia‐
phragm and guide the line out of the holders.

– Disconnect the connector from the Fuel Pressure Regulator

Valve - N276- -arrow-.
– Remove the wiring guide on the rail elements (high pressure
reservoir) and move to the side.
– Remove the vacuum hose -item 11- ⇒ Item 11 (page 84) from
the cylinder head cover.
– Remove the remaining vacuum hoses from the bracket on the
cylinder head cover.
– Disconnect the connector -1- from the Engine Coolant Tem‐

perature Sensor on Radiator Outlet - G83- , open the clamps
-arrows- and remove the toothed belt guard upper section.
– Remove the crankcase ventilation hose between the intake
scoop and the cylinder head cover.
Note
The crankcase ventilation hose is destroyed when it is removed.

ProCarManuals.com
– Remove the high pressure line -item 21-

⇒ Item 21 (page 314) between the high pressure fuel pump
and rail element (high pressure reservoir).
– Remove the high pressure lines -item 5-
⇒ Item 5 (page 312) between the rail element (high pressure
reservoir) and the fuel injectors.
– Remove the bolts -arrows- and remove the rail element (high
pressure reservoir).
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– Remove the fuel injectors. Refer to ksw
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1. Cylinder Head 93
– Remove the cylinder head cover bolts in the sequence

-7 to 1-.
– Remove the cylinder head cover.
Installing:
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• Replace the cylinder head cover gasket if damaged or leaking.
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Refer to Parts Catalog.
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– Then tighten the cylinder head cover bolts in the sequence

-1 to 7-.
– Install the toothed belt guard upper section.

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-arrows- against the cylinder head cover until the clips engage
with each other. Use a screwdriver to press the guard if nec‐
essary.
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– Tighten the highd bpressure
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page 90 , Cylinder Head Cover, Removing and Installing
• Overview - Fuel System. Refer to rrectness of i
⇒ “3.3 Overview - Fuel System”, page 311 .
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1.6 Toothed Belt, Removing, Installing and

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♦ Tensioning Roller Locking Tool - T10265-

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Overview - Toothed Belt Drive. Refer to

⇒ “1.2 Overview - Toothed Belt Drive”, page 43 .
Removing
Requirements
1. Cylinder Head 95
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– Remove the fuel filter. Refer to
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– Disconnect the connector -1- from the Engine Coolant Tem‐
ion
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perature Sensor on Radiator Outlet - G83- , open the clamps
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-arrows- and remove the toothed belt guard upper section.
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⇒ Item 29 (page 45) .
– Remove the toothed belt guard lower section and center sec‐
tion -arrows-.
– Remove the nut from the coolant pipe -1-.

– Rotate the engine to Top Dead Center (TDC) and secure the
crankshaft toothed belt gear using the Crankshaft Stop -
T10100- or the Crankshaft Stop - T10050- . Push the crank‐
shaft stop from the front side of the toothed belt gear into the
teeth. The toothed gear must be in the “12 o'clock” position.
Note
The markings on the crankshaft toothed belt sprocket -2- and the
Crankshaft Stop - T10050- -1- must align. The pin on the Crank‐
shaft Stop - T10050- must engage in the hole on the sealing
flange.
– Mark the toothed belt running direction.
– Loosen the camshaft sprocket bolts -1-.
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– Loosen the tensioning roller nut -1- and turn the tensioning
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1. Cylinder Head 97
– Now turn the tensioning roller eccentric pulley clockwise in di‐

rection of -arrow- all the way and tighten the nut -1- by hand.
– First remove the toothed belt from the idler roller and then from
the remaining sprockets.
Installing
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♦ Adjustments to toothed belt may generally only be performed
when the engine is cold, because the indicator position of the
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tensioning element changes depending on engine tempera‐
ture.
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♦ The engine bracket must be removed in order to replace the
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ProCarManuals.com
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tensioning roller. Refer to
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Procedure
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Pin - 3359- . To do this, push the pin through the empty outer
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oblong hole and into the cylinder head hole.
– Loosen the bolts -1-, which were hand-tightened.

– If necessary, rotate the high pressure fuel pump hub with a

screwdriver at the bolt heads -1- until it can be secured.
AG. Volkswagen AG d
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Pump Locking Pin - 3359- . To do this, slide the pin into the
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– Rotate the camshaft sprocket and fuel high pressure pump
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ProCarManuals.com
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toothed belt sprocket clockwise in their oblong holes as far as
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– Install the toothed belt on the crankshaft toothed belt sprocket,

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– Lay the belt on the last pulley.
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– Loosen the tensioning roller nut and remove the Tensioning
Roller Locking Tool - T10265- .
Note
Make sure the tensioning roller is properly positioned in the rear

toothed belt guard -arrow-.
1. Cylinder Head 99
– Carefully turn the tensioning roller eccentric pulley clockwise

with the Wrench - Tensioning Roller - T10264- until the indi‐
cator is located centrally in the base plate gap -2-.
• Make sure the nut -1- does not rotate with it.
– Hold the tensioning roller in this position and tighten the ten‐
sioning roller nut.
– Position the Counterhold - Kit - Multiple Use - T10172A- as
shown. Push the Counterhold - Multiple Use - T10172A- in the
direction of the arrow and hold the camshaft sprocket preten‐
sioned.
– Tighten the bolts -1- for the camshaft sprocket and the fuel
high pressure pump toothed belt sprocket in this position.
• Tightening specification: 20 Nm.
Volkswa
– Remove the Diesel Injection Pump Locking agPin - .3359- and
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of engine rotation in direction of -arrow- and just before TDC
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– Position the Crankshaft Stop - T10100- or the Crankshaft Stop
ProCarManuals.com
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Note
In the following check, only the camshaft and crankshaft are se‐
cured. The high pressure fuel pump hub mounting point is very
difficult to recover. A small variance -arrow- does not affect engine
operation.
– Check if:
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• The camshaft hub can be locked with the Diesel Injection
lksw
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• The tensioning roller indicator points to theuthcenter
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T10050- toward the back until the pin opens the hole.
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– Rotate the crankshaft opposite the direction of engine rotation
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until it is slightly past TDC.
ole,
spec
– Now rotate the crankshaft slowly in the direction of engine ro‐
t to the co
tation until the camshaft hub can be secured.
– After securing, loosen the bolts on the camshaft toothed belt
sprocket.
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ProCarManuals.com
If the Crankshaft Stop - T10100- or the Crankshaft Stop - T10050-
s
Pin Is to the Left of the Hole:
s o
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– Turn the crankshaft in direction of engine rotation until the
mer
crankshaft stop tab engages the sealing flange.
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– Tighten the camshaft toothed belt sprocket bolts.
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– Now turn the crankshaft in the direction of engine rotation until
the crankshaft stop pin engages the sealing flange.
– Tighten the camshaft toothed belt sprocket bolts.
Continuation
– Remove the Diesel Injection Pump Locking Pin - 3359- and
the Crankshaft Stop - T10100- or the Crankshaft Stop -
T10050- .
– Turn the crankshaft at least two additional turns in the direction
of engine rotation and just before TDC for cylinder 1.
– Check again.
The Camshaft Hub Can Now Be Secured:
– Tighten the bolts as follows:
1. Cylinder Head 101

• Camshaft toothed belt sprocket: 1/8 (45 °) additional turn.

Counterhold with Counterhold - Kit - Multiple Use - T10172-
and Counterhold - Kit - Adapter 4 - T10172/4- .
• Fuel high pressure pump toothed belt sprocket: 1/4 (90 °) ad‐
ditional turn. Counterhold with Counterhold - Kit - Multiple Use
- T10172- and Counterhold - Kit - Adapter 8 - T10172/8- .
– Install the toothed belt guard lower section and center section
-arrows-.
– Install the belt pulley/vibration damper.
– Install the ribbed belt. Refer to n AG. Volkswagen AG do
⇒ “1.4 Ribbed Belt, Removing and Installing”,
olkswage page 47 . es n
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– Install the toothed belt guard upper
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Note
-arrows- against the cylinder head cover until the clips engage
with each other. Use a screwdriver to press the guard if nec‐
essary.
guard upper section.
– Install the right front wheel housing liner. Refer to ⇒ Body
50 ; Noise Insulation .
Further assembly is performed in the reverse order of the remov‐
al. Note the following:
• Route the fuel hoses without kinks.
• Check the fuel hoses for secure fit.
ProCarManuals.com
• Do not interchange the supply and return lines (the return line
is blue or has a blue marking, the supply line is white or has a
white marking).
• Clip the fuel hoses back into the retainers.
– Install the Auxiliary Fuel Pump - V393- . Refer to
– Install the fuel filter. Refer to wage
es n
⇒ “6.3 Fuel Filter, Removing and Installing”, page 251 . y Volks ot g
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– Install the engine cover. Refer to tho
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⇒ “1.4 Engine Cover, Removing and Installing”,s apage 90 .
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♦ Guide Tool - Cylinder Head - 3070-

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♦ Crankshaft Stop - T10050-

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♦ Counterhold - Camshaft Gear - T10051-

♦ Puller - Camshaft Sprocket - T10052-
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♦ Socket - Xzn 10 - T10385-

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DANGER!

tions. Refer to
page 305 .
work.
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Note
♦ Overview - Toothed Belt Drive. Refer to

♦ Overview - Cylinder Head. Refer to
⇒ “1.2 Overview - Cylinder Head”, page 85 .
ments. Refer to
page 290
♦ Overview - Intake Manifold with Attachments. Refer to
⇒ “3.12 Overview - Intake Manifold with Attachments”,
page 331 .
Converter. Refer to
ProCarManuals.com
♦ Overview - EGR Components. Refer to

⇒ “3.1 Overview - Exhaust Gas Recirculation System Com‐
ponents”, page 398 . G. Volkswagen
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♦ Hose connections
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♦ Always
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♦ When replacing the cylinder head or cylinder head gasket, all

spec

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The Battery - A- ground cable must be disconnected for the fol‐
ht
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lowing procedure. For this reason check if a coded radio is in‐
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stalled. If necessary, obtain anti-theft code beforehand.
Prote AG.

WARNING

space.
vacuum lines.
or hot components.

Caution

A- is disconnected:
ProCarManuals.com
♦ Complete the steps for disconnecting

lksw
the Battery - A- .
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– When the ignition
oris
ed
is switched off, disconnect the ground nte cable
-arrow- from
auth the Battery - A- . Refer to ⇒ Electrical Equipment;
eo
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Rep. Gr.
ss 27 ; Battery; Battery, Disconnecting and Connecting c .
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– Remove the cylinder head cover. Refer to

nform
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page 90 .
m
– Remove the toothed belt from the camshaft. Refer to

at
om
io

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page 95 , Toothed Belt, Removing, Installing and Tensioning.

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– Remove the camshaft sprocket and the hub. Refer to

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⇒ “2.2 Camshafts, Removing and Installing”, page 131 , Cam‐

f
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shafts, Removing and installing.

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– Disconnect from the EGR Vacuum Regulator Solenoid Valve

- N18- -1- and from the Throttle Valve Control Module - J338-
-3-.
– Loosen the clamp -4- and remove the charge air hose.
– Remove the oil dipstick bracket -arrow-.
– Remove the air shroud and radiator fans. Refer to
Sensor - G31- .
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– Remove the oil supply line. Refer to

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– Unclip the wiring harness to the Engine Control Module - J623-

from the cable guide -arrow-.
– Remove the vacuum pump. Refer to
⇒ “1.8 Vacuum Pump, Removing and Installing”, page 126 .

Sensor - G581- -2- on the on the turbocharger vacuum dia‐
phragm.
– Disconnect the vacuum hose -3- at the turbocharger vacuum
diaphragm.
ProCarManuals.com
– Disconnect the »black« connector for the Exhaust Gas Tem‐

perature Sensor 1 - G235- -2- at the plenum chamber bulk‐
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– Remove the right drive axle heat shield -arrows-.

– Remove the charge air pipe bolts -item 15-
⇒ Item 15 (page 291) and remove the connecting hose
-item 13- ⇒ Item 13 (page 291) from the pulsation damper on
the turbocharger.
– Mark the installation position for the Exhaust Gas Tempera‐
ture Sensor 1 - G235- -item 37- ⇒ Item 37 (page 274) and
remove it.
– Remove the control line between the EGR housing and the
Exhaust Pressure Sensor 1 - G450- . Refer to
⇒ “1.2 Overview - Particulate Filter with
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⇒ Item 9 (page 399) .
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– Disconnect the connector -arrow- from the Engine Coolant

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– Remove the particulate filter from the upper bracket and loos‐
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– Remove the coolant hoses from the coolant connections on

the cylinder head.
– Remove the bolt -arrow- from the rear toothed belt guard.
– Remove the nut -item 5- ⇒ Item 5 (page 43) from the toothed
belt tensioning roller -item 7- ⇒ Item 7 (page 43) .


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head.
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♦ Carefully remove all lapping and sanding residue.
♦ Only unpack the new cylinder head gasket immediately
before installing.
♦ To prevent the cylinder head gasket silicone layer and re‐
cessed area from being damaged, always handle the seal
extremely carefully.
Risk of damaging open valves:
♦ If a replacement cylinder head is installed, only remove
the accompanying plastic base immediately before instal‐
ling to protect the open valves.
Risk of damaging valves and piston heads after working on the
valvetrain:
♦ To ensure valves do not strike pistons when starting, care‐
fully rotate engine at least two full revolutions.
♦ Before installing, check if the oil return pipe decoupling
element is bent or stretched. If this is the case, there could
be micro tears which could result in leaks. If necessary,
replace the oil return pipe before installing the cylinder
head.

Note
♦ Always replace cylinder head bolts.

♦ Replace gaskets, seals and self-locking nuts and clamps.
♦ Carefully remove residual sealant from cylinder head and cyl‐
inder block. Make sure that no long grooves or scratches
result. When using sand paper, grit must not be below 100.
♦ Thoroughly remove all sanding and lapping residue.
♦ Only unpack the new cylinder head gasket immediately before
installing.
– Before mounting the cylinder head, remove the Crankshaft

Stop - T10050- and rotate the crankshaft back opposite the
direction of engine rotation until all of the pistons are nearly
even under TDC.
– Place the cylinder head gasket with the identification upward.
– To center, slide the Guide Tool - Cylinder Head - 3070- into

the outer holes on the intake side.
Note
ProCarManuals.com
The tensioning roller must be placed on the stud bolt when mount‐
ing the cylinder head.
– Install the cylinder head, insert the eight cylinder head bolts
and tighten them by hand.
– Remove the Guide Pin using the Pin Remover from the Guide
Tool - Cylinder Head - 3070- through the bolt holes and insert AG. Volkswagen
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Step IV = 1/4 (90 °) turn

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1. Position the lower bracket with the nuts on the cylinder block
and on the particulate filter. (Do not tighten the nuts.)
2. Position the new clamp with a new gasket between the par‐
ticulate filter and turbocharger (do not tighten the clamp):
• Make sure the clamp is in the correct installation position. Re‐
fer to
3. Install the EGR filter -item 9- ⇒ Item 9 (page 399) .
4. Position a new clamp between the particulate filter and EGR
filter (do not tighten the clamp):
fer to
5. Position the particulate filter on the upper bracket with the
bolt. (Do not tighten the bolt.)
– Tighten the mounting elements in the following sequence:
6. Clamp between the particulate filter and turbocharger.
7. Lower bracket to the cylinder block:
8. Lower bracket to the particulate filter:
9. Upper bracket to the particulate filter:
10. Upper bracket to the cylinder head:
11. Clamp between the particulate filter and EGR filter:


lowing:
• The self-locking nuts and seals must be replaced.
• Position the charge air pipe connecting hose before securing
the turbocharger.
• Pay attention to the installation position of the Exhaust Gas
Temperature Sensor 1 - G235- .
• Replace the banjo bolt with the turbocharger support gaskets
as well as the oil return pipe O-rings.
• Do not stretch the oil return pipe decoupling element when
installing the turbocharger support.
– Install the cylinder head cover. Refer to
page 90 .
ProCarManuals.com
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mission 02Q; Rep. Gr. 34 .
Transmission 02E; Rep. Gr. 34 .
• Overview - Toothed Belt Drive. Refer to
• Overview - Cylinder Head Cover. Refer to
• Overview - Cylinder Head. Refer to
• Overview - Turbocharger with Exhaust Manifold and Attach‐
ments. Refer to
• Overview - Charge Air Cooler Components. Refer to
page 290 .
ProCarManuals.com
• Overview - Intake Manifold with Attachments. Refer to

page 331 .
• Overview - Particulate Filter with NOx Reduction Catalytic
Converter. Refer to
AG. Volkswagen AG d
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1.7.2 Cylinder Head, Removing and Installing, Engine Codes CBDA, CBDB and
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equipment required
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♦ Guide Tool - Cylinder Head
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Locking Pin - 3359-
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♦ Counterhold - Camshaft
Gear - T10051-
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♦ Puller - Camshaft Sprocket
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♦ Socket - Xzn 10 - T10385-
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DANGER!

tions. Refer to
page 305 .
work.

Note
♦ Overview - Toothed Belt Drive. Refer to

♦ Overview - Cylinder Head. Refer to
ments,. Refer to
⇒ “3.3 Turbocharger with Exhaust Manifold, Removing and
Installing, Engine Codes CBDA, CBDB, CEGA”, page 279 .
page 290
♦ Overview - Intake Manifold with Attachments. Refer to
page 331 .
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or hot components.
– Disconnect the battery ground cable when the ignition is

switched off. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
Battery; Battery, Disconnecting and Connecting .


Installing .
– Remove the air shroud with the Radiator Fan - V7- and Radi‐
ator Fan 2 - V177- . Refer to
– Remove the »cold side« hose from the charge air cooler
page 90 .
– Remove the toothed belt from the camshaft. Refer to
page 95 .
– Disconnects from the EGR Vacuum Regulator Solenoid Valve
- N18- -1- and from the Throttle Valve Control Module - J338-
-3-.
ProCarManuals.com
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– Remove oristhe
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bolts from the oil dipstick connection n-arrow-
tee and
fromauthe
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EGR connecting pipe -2-. or
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– Remove the air shroud and radiator fans. Refer to
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– Disconnect the vacuum line from the vacuum pump. tho or
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ProCarManuals.com
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– Disconnect the connector -arrow- from the Engine Coolant
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Note
The lower bolt on the EGR cooler is removed with the Socket -
Xzn 10 - T10385- .


– Remove the nuts -arrows- on the particulate filter bracket -A-

from the crankcase.
– Loosen the clamp between the turbocharger and the particu‐
late filter.
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– Remove the connecting pipe -A- to the EGR cooler.

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– Remove the screw -arrow- from the support on the turbo‐

charger.
– Remove the coolant hoses from the coolant connections on
the cylinder head.

– Remove the oil supply line bolt -arrow- and then remove the
oil supply line.
– Remove the camshaft toothed belt sprocket and remove the
camshaft hub using the Puller - Camshaft Sprocket - T10052- .
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– Follow the sequence when loosening the cylinder head bolts.
Note
♦ A second technician is needed to remove the cylinder head.

♦ The toothed belt tensioning roller is pulled off the stud bolt
when prying the cylinder head out.
♦ The turbocharger oil return line is pulled out of the support
when lifting the cylinder head out.
– Lift the cylinder head first on the transmission side and guide
it out of the toothed belt guard. Be careful not to let the toothed
belt tensioning roller fall.
– Lay the cylinder head down so that the oil return line is not
bent. Place a wooden block under the exhaust manifold if nec‐ agen AG. Volkswagen AG do
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There is a risk of damaging sealing surfaces:
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ProCarManuals.com
♦ Carefully remove the sealant residue from the cylinder

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head and cylinder block.
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♦ Make sure that no long grooves or scratches result.
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Risk of damaging the cylinder block:
♦ There must be no oil or coolant in the blind holes for the
cylinder head bolts in the cylinder block.
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Risk of the cylinder head gasket leaking:
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♦ Carefully remove all lapping and sanding residue.
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♦ Only unpack the new cylinder head gasket immediately

before installing.
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♦ To prevent the cylinder head gasket silicone layer and re‐
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Risk of damaging valves and piston heads after working on the
valvetrain:
♦ To ensure valves do not strike pistons when starting, care‐
fully rotate engine at least two full revolutions.
♦ Before installing, check if the oil return pipe decoupling
element is bent or stretched. If this is the case, there could
be micro tears which could result in leaks. If necessary,
replace the oil return pipe before installing the cylinder
head.

Note
♦ Always replace cylinder head bolts.

♦ Carefully remove residual
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♦ Handle the seal carefully. Damages to the silicone layer and
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in areas of recesses may result in leaks.
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– Before mounting the cylinder head, remove the Crankshaft
hole
spec
Stop - T10050- and rotate the crankshaft back opposite the
es, in part or in w
direction of engine rotation until all of the pistons are nearly
t to the co
even under TDC.
– Place the cylinder head gasket with the identification upward.
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– To center, slide the Guide Tool - Cylinder Head - 3070- into

the outer holes on the intake side.
nform
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ProCarManuals.com
Note
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The tensioning roller must be placed on the stud bolt when mount‐
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Tool - Cylinder Head 3070, and then insert the cylinder head
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– Tighten the cylinder head in the tightening sequence, in four

stages as follows:
1- Tighten using Torque Wrench:
Step I = 30 Nm
Step II = 50 Nm
2- Tighten further using a solid wrench:
Step III = 1/4 (90 °) turn
Step IV = 1/4 (90 °) turn

– Secure the rear toothed belt guard on the cylinder head.
– Install the hub and the camshaft sprocket.
– Use the Diesel Injection Pump Locking Pin - 3359- to secure
the camshaft and the high pressure pump.

– Turn the crankshaft in the direction of engine rotation to TDC

and secure the crankshaft with the Crankshaft Stop - T10050- .
– Install the toothed belt. Refer to ⇒ , page 98 .
lowing:
page 90 .
– Install the ribbed belt. Refer to
– Fill the coolant. Refer to
– Perform a road test and check the DTC memory.
1.8 Vacuum Pump, Removing and Installing
AG. Volkswagen AG d
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♦ When replacing the cylinderorise
head or cylinder head gasket, all nte
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of the coolant must be
s aureplaced.
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♦ After working on the valvetrain and engine, carefully rotate by ility
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inform
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Do not disassemble the vacuum pump under any circumstan‐

atio
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ces because it can cause the vacuum component to malfunc‐

o
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tion. The result would be brake booster failure.

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Removing:
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– Remove the vacuum hose -1- from
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– Remove the charge air pipe ris bolts -item 15-
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⇒ Item 15 (page 291) and
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downward to reach thess rear threaded connection on the vac‐ c
uum pump.
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– Remove the vacuum pump -4- from the cylinder head.
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• Make sure that vacuum pump coupling has proper seating in
camshaft.
• Always replace the vacuum pump seal.
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– Install the vacuum pump -4- and tighten the bolts -arrows-.
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– Tighten the charge air pipe bolts -item 15-
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⇒ Item 15 (page 291) .
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– Connect the brake booster vacuum hose -1- to the vacuum

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– Install the air filter housing. Refer to
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1.9 Compression, Checking
Note
The compression can also be checking. Refer to Vehicle Diag‐

nostic Tester .

♦ Compression Tester Kit - Adapter 12 - VAG1381/12-
♦ Compression Tester Kit - VAG1763-
Test Conditions
• Engine oil temperature must be at least 30 °C (86 °F).
• The battery voltage must be at least 12.7 V.
• All electrical consumers for example lamps and rear window
defogger, must be switched off.
Test Sequence
– Remove the glow plug from the applicable cylinder. Refer to
⇒ “1 Glow Plugs”, page 408 .
– Install the Compression Tester Kit - Adapter 12 - VAG1381/12-
in place of the glow plugs.
– Check compression using the Compression Tester Kit -
VAG1763- .

Note
Refer to the Operating Instructions for information on using the

tester.
– Operate the starter until the Tester shows no further pressure

increase.
Compression Values:
• New: 25.0 to 31.0 bar (362.59 to 449.617 psi) pressure
• Wear limit: 19.0 bar (275.57 psi) pressure
• Permissible difference between all cylinders: maximum 5.0
bar (72.51 psi)
– Install the glow plug in the applicable cylinder. Refer to
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By separating the connections,
ss a DTCs will be stored. After the test, c
check the DTC memory and erase, if necessary.
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ProCarManuals.com
– Check the DTC memory for the Engine Control Module - J623-
erm
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and erase all of the DTC entries. Refer to Vehicle Diagnostic
ility
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AG. Volkswagen AG d
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2 Valvetrain
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⇒ “2.1 Overview
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⇒ “2.2 Camshafts, Removing and Installing”, page 131

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⇒ “2.3 Camshaft Seal, Removing and Installing”, page 137
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⇒ “2.4 Valve Stem Seals with Cylinder Head Installed, Replacing”,
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⇒ “2.5 Valve Guides, Checking”, page 141
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Note
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♦ The plastic protectors installed to protect the open valves must
only be removed just before mounting the cylinder head.
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♦ When replacing the cylinder head or cylinder head gasket, the
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coolant must be completely replaced.

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♦ Do not start the engine for approximately 30 minutes after in‐
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fo
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ProCarManuals.com
selves (otherwise the valves will crash into the pistons).

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pistons when starting. Prote
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♦ Always replace the gaskets and seals.
2.1 Overview - Valvetrain
2. Valvetrain 129
1 - Seal
lip on the seal with oil or
grease
❑ Before installing, re‐
move the oil residue
from camshaft journal
with a clean cloth
❑ To install, tape over the
groove on the camshaft
cone.
ling. Refer to
⇒ “2.3 Camshaft Seal,
ling”, page 137 .
2 - Bolt
❑ 10 Nm
3 - Nut
❑ 10 Nm
4 - Bearing Frame
❑ Observe the sequence
for loosening and tight‐
ProCarManuals.com
ening. Refer to
⇒ “2.2 Camshafts, Re‐
moving and Installing”,
page 131 , Camshafts,
Removing and Installing AG. Volkswagen AG d
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5 - Exhaust Camshaft aut ra
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6 - Intake Camshaft
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❑ Removing and installing. Refer to ⇒ “2.2 Camshafts, Removing and Installing”, page 131 .
t to the co
7 - Roller Rocker Lever

❑ Mark the installed position
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❑ Check the roller bearing for ease of movement
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❑ Lubricate the running surfaces before installing

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8 - Hydraulic Lifter
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❑ Lubricate the running surfaces before installing

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❑ Valve Dimensions. Refer to ⇒ Fig. ““Valve Dimensions”“ , page 131 .
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❑ Valve Guides, Checking. Refer to ⇒ “2.5 Valve Guides, Checking”, page 141 .
Prote AG.
10 - Cylinder Head
❑ Observe the notes. Refer to ⇒ page 129 .

❑ Checking for distortion. Refer to ⇒ Fig. ““Cylinder Head, Checking for Distortion”“ , page 86 .
❑ Removing and installing. Refer to ⇒ “1.7 Cylinder Head, Removing and Installing”, page 103 .
❑ All of the coolant must be replaced after installing
11 - Valve Stem Seal
Replacing. Refer to ⇒ “2.4 Valve Stem Seals with Cylinder Head Installed, Replacing”, page 138 .
12 - Valve Spring
13 - Valve Spring Retainer
14 - Cone Piece
15 - Cap
❑ Replace
❑ Drive in flush using a suitable drift
Valve Dimensions
Note
Intake and exhaust valves must not be reworked. Only lapping is

permitted.
ProCarManuals.com
Dimension Intake Valve Exhaust Valve

Diameter mm 26.60 26.00
a
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2.2 Camshafts, Removing and Installing
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♦ Camshaft Fitting Tool - T40094A-

♦ Camshaft Fitting Tool - T40095-
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♦ Camshaft Fitting Tool - T40096 - T40096-

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♦ Silicone Sealant - D 176 501 A1- . Cop py
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131
Prote AG.
2. Valvetrain
⇒ , page 133 .
Removing
– Remove the toothed belt from the camshaft and the high pres‐
sure fuel pump. Refer to
page 90 .
– Remove the bolts -1- for camshaft sprocket.
– Remove the camshaft sprocket from the hub.
AG. Volkswagen AG d
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– Counterhold the hub with the Counterhold - Camshaft Gear -

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T10051- and loosen the hub bolt -1-.
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– Unscrew the bolt for the hub by approximately two turns.
spec
es, in part or in w
t to the co
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– Mount the Puller - Camshaft Sprocket - T10052- and align the
n
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Puller - Camshaft Sprocket to the holes in the hub.

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– Tighten the bolts -1-.

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– Tighten the Puller -2- evenly to tension the hub until the hub
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loosens from the camshaft cone. Cop py
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Hold the Puller at the same time with a 30 mm wrench.
– Remove the hub from the camshaft cone.

– Remove the vacuum pump. Refer to

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Golf Variant 2007 ➤ , Golf ir se Variant 2010 ➤ , Jetta 2005 ➤ , Jettaa2011
d r n
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– Remove the bearing frame bolts or nuts in the sequence
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-24 to 1-.
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– Remove the bearing frame.
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– Carefully remove the camshafts.
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Installing:
spec
es, in part or in w
t to the co
Note
rrectness of i
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♦ Seal the separating surface between the bearing frame and
the cylinder head with Silicone Sealant - D 176 501 A1- .
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♦ The camshafts may only be installed using the Camshaft

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Fitting Tool - T40094- as described below. Otherwise the
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axial bearing in the bearing frame will be destroyed and
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the cylinder head will have to be replaced.

t.
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♦ Make sure that no sealant residue enters the cylinder head
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or the bearings.
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ProCarManuals.com
Prote AG.
WARNING
Wear protective eyewear.
– Remove any sealant residue from the cylinder head and on

the bearing frame using, for example, a rotating plastic brush.
– Clean the sealing surfaces, they must be free of oil and grease.
– Oil the contact surfaces of the camshafts.
Assemble the Camshaft Fitting Tool - T40094- as follows:
– Remove the Camshaft Fitting Tool - Mounts - T40094/3- , -

T40094/4- and - T40094/5- from the base plate. Loosen the
threaded connections from below.
Note
If the Camshaft Fitting Tool - T40094A- mounts are not marked,

mark the removed mounts, for example, with numbers, to assure
it can be assembled later.
2. Valvetrain 133
– Instead, mount the Camshaft Fitting Tool - Mounts - T40094/9-

and - T40094/10- in the empty outer locations.
– Place the Camshaft Fitting Tool - Mount - T40094/2- at position
“A” and Camshaft Fitting Tool - Mount - T40094/1- at position
“F”.
AG. Volkswagen AG d
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– First install the intake camshaft
rise
d b
as shown. Make sure the re‐ arant
cess -arrow- for the ucylinder
tho head bolt faces »outward«. ee
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– Install a 0.50 mm sfeeler gauge and push the Camshaft Fitting
ce
le
Tool - Mount - T40094/8- into the groove on the intake cam‐

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– Now insert the exhaust camshaft.
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ProCarManuals.com
rrectne
– Secure the exhaust camshaft above its groove -arrow- using
the Camshaft Fitting Tool - Cover - T40094/11- .
ss
– Mount the Grip Jaws - T40096/1- on the exhaust camshaft
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Make sure the clamping bracket marked with an arrow is on

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– Tighten the Grip Jaws - T40096/1- with the thumbwheel until
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the tooth flanks align. If necessary use a 13 mm open end
AG.
wrench.
– Slide the intake camshaft toward the exhaust camshaft until
the splines are engaged.
– Position the bearing frame on the camshafts.
• All the camshaft bearings must lie on the camshafts.

– Position the Camshaft Fitting Tool - T40095A- as shown and

secure the camshafts in the bearing frame.
– Remove the Cover - T40094/11- .
– Remove the Mount - T40094/8- from the groove in the intake
camshaft.
AG. Volkswagen AG d
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– Cut the tube nozzle
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ProCarManuals.com
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– Apply Silicone Sealant as shown on the clean cylinder head
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sealing surface. The sealing compound bead must be:

• 2 to 3 mm thick nf
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• Run around inside in the area of the bolt holes

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– Remove the camshafts together with the bearing frame and copy Vo
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Tool - T40094- .
– Carefully insert the camshafts and bearing frame in the cylin‐
der head.
2. Valvetrain 135
– First tighten the bearing frame bolts or nuts by hand in the

sequence -1 to 24-.
• The guide frame must contact the entire contact surface of the
cylinder head.
– Tighten the bearing frame bolts or nuts in the sequence
-1 to 24-.
• Tightening specifications -item 2- ⇒ Item 2 (page 130) and
– Remove the Camshaft Fitting Tool - T40095- and the Grip
Jaws - T40096/1- .
– Replace the camshaft seal. Refer to
⇒ “2.3 Camshaft Seal, Removing and Installing”, page 137 .
– Drive a new cap -item 15- ⇒ Item 15 (page 131) onto the cyl‐
inder head with a suitable drift until it is flush.
The rest of the installation is performed in reverse order of re‐
moval, while doing so pay attention to the following:
Note

stalling the camshafts. The hydraulic lifters must seat them‐
ProCarManuals.com

♦ After working on the valvetrain, carefully rotate engine by hand
at least two full revolutions to ensure that valves do not strike
the pistons when starting.
– Place the hub onto the camshaft.
– Counterhold the hub with the Counterhold - Camshaft Gear -

T10051- and tighten the hub bolt -1-.
• Tightening specifications. Refer to -item 11-
⇒ Item 11 (page 44) . n AG. Volkswagen AG do
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Rep. Gr.15 - Cylinder Head, Valvetrain Prote AG.
– Push the camshaft sprocket onto the hub.
Note
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The toothed segment yV
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– Install the bolts -1- into the camshaft sprocket by hand without
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– Lock the hub with the Diesel Injection Pump Locking Pin -
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– Install the vacuum pump. Refer to
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page 90 .
2.3 Camshaft Seal, Removing and Installing
nform
mercia
a
ProCarManuals.com

com
tion in
♦ Seal Installer - Crankshaft/Camshaft - 10-203-
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Removing
– Remove the camshaft sprocket and the hub. Refer to
– Insert the Puller - Camshaft Seal Supplement -3240/1- into the
camshaft.
– Remove the inner section of the Puller - Camshaft Seal - 3240-
two rotations (approximately 3 mm) from the outer section and
secure with a knurled bolt.
2. Valvetrain 137
– Lubricate the threaded head on the Puller - Camshaft Seal -

3240- position it and install it as far as possible into the seal
using force.
– Loosen the knurled bolt and turn inner section against cam‐
shaft until the seal is removed.
Installing:
Note
The sealing lip of the seal may not be additionally oiled or

greased.
– Clean off any oil residue on the camshaft pin with a clean cloth.
– Mount the guide sleeve from the Puller - Camshaft Seal - 3240-
on the camshaft as shown.
– Carefully slide the shaft seal -1- over the guide sleeve and onto
the camshaft.
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– Press the seal in the thrust piece from the Seal Installer -
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♦ Valve Keeper Tool Kit - VAS5161A-
Removing:
– Remove all the glow plugs. Refer to
– Remove the camshafts. Refer to
⇒ “2.2 Camshafts, Removing and Installing”, page 131 .

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– Insert the Valve Cotter Tool Update Kit - Punch - VAS5161/3-

into the Guide Plate and loosen the stuck valve retainers with
a plastic mallet.
2. Valvetrain 139
– Install the Valve Cotter Tool Kit - Guide Forks M6/M8 with
Threaded Studs - VAS5161/5- using the Valve Cotter Tool Kit
- Retainer - VAS5161/6- into the Guide Plate .
– Slide the Valve Cotter Tool Kit - Guide Plate Sleeve -
VAS5161/23-1- onto the Valve Cotter Tool Kit - Assembly
Cartridge - VAS5161/8A- .
– Connect the Valve Cotter Tool Kit - Adapter - VAS5161/11- to
compressed air with a commercially available connector and
apply constant pressure.
• Minimum pressure: 6 bar (87.02 psi)
– Engage the Valve Cotter Tool Kit - Pressure Fork with Lever
for Assembly Cartridge - VAS5161/2- on the Valve Cotter Tool
Kit - Retainer and press the Assembly Cartridge downward.
– At the same time, turn the Assembly Cartridge knurled bolt to
the right until the points engage in the valve retainers.
– Move the knurled bolt gently back and forth, causing the valve
retainers to be pressed apart and gripped in the Assembly
Cartridge .
– Release the Pressure Fork .
– Remove the Assembly Cartridge with the Knurled Spacer
Ring , the valve plate and the valve spring.
ProCarManuals.com
Note
olkswagen AG
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The Valve Seal Removal Tool - 3064- is shown,olks the Puller - Valve
wag does
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Seal - 3364- is used for removing the evalve
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– Pull off valve stem seals using the Puller - Valve Seal - 3364- .
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Note
A plastic sleeve -A- is supplied with the new valve stem seals.
– Place the plastic sleeve -A- on valve stem to prevent damage

to new valve stem seals -B-.
– Lightly oil the sealing lips of the valve stem seal -B-.
– Push the valve stem seal -B- on the plastic sleeve -A-.
– Carefully press valve stem seal onto valve guide using Seal
Installer - Valve Stem - 3365- .
– Tap lightly on the driver with a plastic mallet until the valve
stem seal is at the stop.
– Remove the plastic sleeve -A- again.
– Insert the valve spring and valve plate in the cylinder head.
– If the valve retainers were removed from the Assembly Car‐

tridge , they must first be inserted into the Valve Keeper Tool
Kit - Valve Insertion Device - VAS5161/18- .
Note
ProCarManuals.com
The large diameter of the valve retainers point upward.
– Press the Assembly Cartridge onto the Insertion Tool from

above and remove the valve retainers.
– Insert the Valve Keeper Tool Kit - AssemblyeCartridge

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⇒ “2.2 Camshafts, Removing and Installing”, page 131 .

h re
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Note

rrectness of i
stalling the camshafts. The hydraulic lifters must seat them‐

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♦ After working on the valvetrain, carefully rotate engine by hand

at least two full revolutions to ensure that valves do not strike
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– Install all the glow plugs. Refer to

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2.5 Valve Guides, Checking

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2. Valvetrain 141

Test Sequence
– Insert a new valve into the guide. The end of the valve stem
must be flush with the guide. Use only the intake valve in the
intake guide or the exhaust valve in the exhaust guide.
– Determine the tilting clearance.
• Wear limit: 1.30 mm
– If the tilting clearance exceeds the wear limit, the cylinder head
must be replaced.
ProCarManuals.com
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3 Special Tools

equipment required
Locking Pin - 3359-
or Crankshaft Stop -
T10050- (is shown)
♦ Counterhold - Multiple Use
- T10172A-
♦ Wrench - Tensioning Roller
- T10264-
♦ Tensioning Roller Locking
Tool - T10265-
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3. Special Tools 143

♦ Seal Installer - Crankshaft/

Camshaft - 10-203-
♦ Puller - Camshaft Seal -
3240-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ M12x65 bolt
ProCarManuals.com
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5-50Nm - VAG1331-
40-200Nm - VAG1332-
VAS6208-
♦ Engine Bung Set -
VAS6122- (not illustrated)
ProCarManuals.com
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♦ Guide Tool - Cylinder Head

- 3070-
Locking Pin - 3359-
Gear - T10051-
♦ Puller - Camshaft Sprocket AG. Volkswagen AG d
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♦ Socket - Xzn 10 - T10385- orise nte
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ProCarManuals.com
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Golf Variant 2007 ➤ , Golf Variant a2010
gen AG➤ , Jetta 2005
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4-Cylinder Diesel Engine (2.0L
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♦ Diesel Injection Pump ss
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Locking Pin - 3359-
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Gear - T10051-
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♦ Camshaft Fitting Tool -
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T40094A-
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♦ Camshaft Fitting Tool -
T40095-
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♦ Camshaft Fitting Tool - l purpos
T40096 - T40096-
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♦ Seal Installer - Valve Stem
- 3365-
5-50Nm - VAG1331-
♦ Valve Keeper Tool Kit -
VAS5161A-
ProCarManuals.com
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♦ Compression Tester Kit - VAG1763-
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♦ Dial Gauge Holder - VW387-
♦ Not Illustrated:
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♦ Guide Tool - Cylinder Head - 3070-
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ProCarManuals.com
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♦ Camshaft Fitting Tool - T40094A-
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♦ Camshaft Fitting Tool - T40095-

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17 – Lubrication
1 Engine Oil
Note
The oil level must not go above the MAX mark - danger of causing
damage to the catalytic converter! Markings. Refer to
⇒ “1.2 Engine Oil, Checking Level”, page 151 .
Draining the Engine Oil. Refer to ⇒ Maintenance ; Booklet 20.1 ;

Procedure Descriptions; Engine Oil, Draining or Extracting and
Filling, Replacing Oil Filter .
Engine Oil Specification. Refer to the ⇒ Maintenance Intervals;
Rep. Gr. 03 .
⇒ “1.1 Oil Capacities”, page 151
⇒ “1.2 Engine Oil, Checking Level”, page 151
1.1 Oil Capacities

⇒ “1.1.1 Engine Code CBEA”, page 151
ProCarManuals.com
⇒ “1.1.2 Engine Code CJAA”, page 151
1.1.1 Engine Code CBEA

Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
– If necessary, fill up to the MAX mark on the oil dipstick. Refer
to ⇒ “1.2 Engine Oil, Checking Level”, page 151 .
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– If necessary, fill up to the MAX mark on the oil dipstick.
h or Refer eo
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to ⇒ “1.2 Engine Oil, Checking Level”, page 151
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1.2 Engine Oil, Checking Level

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The oil level must not go above the MAX mark - danger of causing
spec
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Test Conditions
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• Engine oil temperature: minimum 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
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back into oil pan.

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Test Sequence
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– Pull out the oil dipstick, wipe off with a clean cloth and insert it
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– Remove the dipstick again and check the oil level.

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1. Engine Oil 151

Range of markings on dipstick:

1 - MIN Mark
2 - MAX Mark
a - Oil level is near the MIN mark: add oil.
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b - Oil level in the center: engine oil can be filled.
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c - Oil level is near the MAX mark: do notoadd ris engine oil.
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The engine oil level may stay in the -d- range due to fuel entering
h re
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the oil or unfavorable operating conditions after filling. This is nor‐
spec
mal and will correct itself. Engine oil does not need to be drained.
t to the co
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ProCarManuals.com
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152 Rep. Gr.17 - Lubrication

2 Lubrication System Components,

Engine Code CBEA
⇒ “2.1 Overview - Oil Pump, Oil Pan and Balance Shaft Assem‐
bly”, page 153
⇒ “2.2 Oil Pan, Removing and Installing”, page 156
⇒ “2.3 Oil Pump, Removing and Installing”, page 158
⇒ “2.4 Balance Shaft Assembly, Removing and Installing”,
page 159 olkswage es n
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⇒ “2.5 Spur Gear, Removing from
ris Crankshaft and Shrink-Fitting
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Caution
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If large quantities of metal shavings or abraded material are
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connecting rod bearings are damaged. To prevent subsequent
h re
damage, perform the following steps after the repair:
ole,
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t to the co
ProCarManuals.com
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ss o
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2.1 Overview - Oil Pump, Oil Pan and Bal‐
form
mer
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“Pay attention to the warnings”. Refer to ⇒ page 153 . n thi

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Oil spray nozzle and pressure relief valve. Refer to

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⇒ Fig. ““Oil Spray Jet and Pressure Relief Valve”“ , page 156 .
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2. Lubrication System Components, Engine Code CBEA 153

1 - Oil Pan
ling. Refer to
⇒ “2.2 Oil Pan, Remov‐
ing and Installing”, page
156 .
2 - Bolt
❑ 10 Nm
3 - Intake Tube
❑ Clean the screen if there
are debris
4 - Bolt
❑ 10 Nm
5 - O-Ring
❑ Replace
6 - Oil Pump
ling. Refer to
⇒ “2.3 Oil Pump, Re‐
page 158 .
ProCarManuals.com
❑ Before installing, check

if both alignment
sleeves for centering
the oil pump on the bal‐
ance shaft assembly are
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8 - Circlip tho tee
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❑ Replace
11 - Hub
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❑ Replace
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❑ For the intermediate sprocket

12 - Bolt
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❑ Replace
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13 - Axial Bearing Disc

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❑ Replace Prote AG.
❑ To achieve the correct backlash, a coating is applied to the intermediate sprocket. The correct play
adjustment is made through the wear.

❑ For the correct installation position, a white dot is applied on the intermediate sprockets with coating on
parts of the circumference
❑ If there is no white dot, the entire circumference of the intermediate sprocket is coated.
Caution
When installing the inter‐
mediate sprocket, make
sure the axial bearing
disc is seated correctly.
Refer to
⇒ Fig. ““Axial Bearing agen
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⇒ “2.4 Balance Shaft Assembly, Removing and Installing”, page 159 ; Balance Shaft Assembly, Re‐
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15 - Axial Bearing Disc
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❑ Replace
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❑ Note the installation position Refer to ⇒ Fig. ““Axial Bearing Disc Installation Position”“ , page 156 .
❑ If necessary, secure to the housing with lubricant to install the intermediate sprocket
ProCarManuals.com
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16 - Crankshaft Spur Gear
l purpos
❑ Spur Gear, Removing from Crankshaft and Shrink-Fitting a New Spur Gear. Refer to
⇒ “2.5 Spur Gear, Removing from Crankshaft and Shrink-Fitting New Spur Gear”, page 166 .
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17 - Balance Shaft Assembly

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⇒ “2.4 Balance Shaft Assembly, Removing and Installing”, page 159 .
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❑ Before installing, check if both alignment sleeves for centering the balance shaft assembly on the cylinder
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❑ M8 bolt:
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❑ 20 Nm + 90° (1/4) additional turn

❑ Replace
❑ Note the tightening sequence. Refer to
⇒ “2.4 Balance Shaft Assembly, Removing and Installing”, page 159 , Balance Shaft Assembly, Re‐
19 - Oil Intake Pipe
20 - Bolt
❑ 10 Nm
21 - Bolt
❑ 40 Nm
22 - Bolt
❑ 45 Nm
23 - Bolt
❑ 15 Nm
❑ Tighten diagonally in steps

24 - Seal
❑ Replace
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25 - Oil Drain Plug olksw not
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Oil Spray Jet and Pressure Relief Valve
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Note
When replacing the oil injector jet, pay attention to the correct
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allocation for the pistons. Refer to Parts Catalog
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“Pay attention to the warnings”. Refer to ⇒ page 153 .
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Axial Bearing Disc Installation Position

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Caution
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Make sure the axial bearing disc -A- does not slip out of the
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2.2 Oil Pan, Removing and Installing

♦ T Bar And Socket - 10mm - 3185-
♦ Hex Ball Socket - T10058-
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Silicone Sealant - D 176 404 A2-
Removing:
– Drain the engine oil. Refer to ⇒ Maintenance ; Booklet 20.1 ;
Procedure Descriptions .
Note
Follow all waste disposal regulations!

– Install the insulation on the oil pan.

– Remove the bolts connecting the oil pan and transmission.
– Remove the oil pan.
– Tap the oil pan lightly with a rubber hammer to loosen it, if
necessary.
– Remove the sealant residue from cylinder block with a flat-
blade scraper.
WARNING
– Remove the sealant residue on the oil pan using a rotating

brush such as a hand drill with a plastic brush attachment.
grease.
Installing:
Note
ProCarManuals.com

olkswagen AG
en AG. V
♦ The oil pan must be installed within
Vol
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– Cut the tube nozzle at front marking (nozzle diameter: approx‐

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excess sealant could get into oil pan and block the screen in the
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oil pump intake tube.

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– Apply the Silicone Sealant as shown on the clean oil pan seal‐
ing surface. The sealing compound bead must be:
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• 2 to 3 mm thick
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• run around inside of bolt holes -arrows-

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– Apply Silicone Sealant to the clean oil pan sealing surface as

shown. (The illustration shows the location of the sealant bead
on the cylinder block.)
– Position the oil pan immediately and gently tighten the bolts
connecting the oil pan to the transmission and all of the oil pan
bolts. Make sure the oil pan lies flush on the intermediate plate/
transmission flange. . Volkswage AG n AG d
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– Tighten the oil pan bolts in a diagonal sequence.
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– Tighten the oil pan/cylinder block bolts.
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– Tighten the oil pan/transmission bolts.
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After installing the oil pan, allow the Sealant to dry for approxi‐
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mately 30 minutes. Only afterward may the engine oil be replen‐

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Special tools and workshop equipment required Prote
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agen

Removing:
– Remove the oil pan. Refer to
⇒ “2.2 Oil Pan, Removing and Installing”, page 156 .

– Remove the circlip -1- with locking ring pliers.

– Install an M3 bolt -2- and remove the input shaft from the oil
pump in direction of -arrow-.
– Remove the screw -4- and remove the intake tube from the oil
pump.
– Remove the bolts -3 and 5- and the oil pump.
Caution
Do not loosen the bolt on the intermediate sprocket.
Installing:
• Replace the O-ring.
• Replace damaged or stretched circlips.
• The circlip must lie in the base of the groove.
⇒ “2.1 Overview - Oil Pump, Oil Pan and Balance Shaft As‐
sembly”, page 153 , Overview - Oil Pump, Oil Pan and Balance
Shaft Assembly
ProCarManuals.com
– Check that the alignment sleeves to center the oil pump on the
balance shaft assembly are present before installing the oil
pump.
– Install the oil pan. Refer to
⇒ “2.2 Oil Pan, Removing and Installing”, page 156 . n AG. Volkswagen AG do
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⇒ “2.4.1 Balance Shaft Assembly, Removing”, page 159 .

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⇒ “2.4.2 New Balance Shaft Assembly, Installing”, page 161
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♦ Crankshaft Stop - T10100- or the Crankshaft Stop - T10050-

for engines with a round crankshaft toothed belt sprocket
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♦ Locking Tool - T10255-

l purpos

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– Remove the belt pulley/vibration damper -item 29-

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⇒ Item 29 (page 45) .

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– Remove the toothed belt guard lower section -item 25-

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⇒ Item 25 (page 44) .

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– Remove the oil pan. Refer to

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– Rotate the engine to TDC and secure the crankshaft toothed

belt sprocket with the Crankshaft Stop - T10050- . Push the
crankshaft stop from the front side of the toothed belt sprocket
into the splines. The camshaft toothed segment must be in the
»12 o'clock« position.
Note
The markings on the crankshaft toothed belt sprocket wag-2-

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Crankshaft Stop - T10050- -1- must align. The y pin
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– Remove the bolts in the sequence -8 to 1- and remove the
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balance shaft assembly with the oil pump.
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Loosening Sequence - Balance Shaft Module with Six Attachment
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– Remove the bolts in the sequence -6 through 1- and remove
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Refer to
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⇒ “2.4.2 New Balance Shaft Assembly, Installing”, page 161 Prote AG.
Refer to
⇒ “2.4.3 Used Balance Shaft Assembly, Installing”, page 165

2.4.2 New Balance Shaft Assembly, Installing

Conditions
• Crankshaft secured using the Crankshaft Stop - T10100- or
AG. Volkswagen AG d
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♦ The balance shaft assembly
ss a spur gear drive must be installed c
with the correct backlash.
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♦ A coating is applied to the new intermediate sprocket to ach‐

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ieve the correct backlash.
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♦ When the intermediate sprocket has a white dot, only sections
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of the circumference are coated. When there is not a white dot,
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spec
coated.
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♦ The coating wears off in a short period of time and this ensures
the correct backlash.
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♦ For this reason, a new balance shaft assembly must always
be installed in conjunction with a new intermediate sprocket
l purpos
with coating.
♦ Only intermediate sprockets with a partial coating have a white
nform
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ProCarManuals.com
dot to indicate the correct installation position.

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♦ No installation position must be observed for intermediate
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sprockets with coating on the entire circumference.
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♦ Replace the bolts which have been tightened to torque.

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♦ The intermediate sprocket threaded connection must be
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loosened to position the balance shaft assembly. When Prote AG.
doing so, make sure the bolt is not loosened too much.
Otherwise the bearing disc could slip behind the inter‐
mediate sprocket.
♦ Axial bearing disc installation position. Refer to
⇒ Fig. ““Axial Bearing Disc Installation Position”“ ,
page 156 .
– Loosen the bolt -1- for the intermediate sprocket approximate‐

ly 45° (1/8 turn) before mounting the balance shaft assembly
on the cylinder block.
– Check that the alignment sleeves for centering the balance
shaft assembly on the cylinder block are present.

– Place the balance shaft assembly on the cylinder block and

make sure the partially-coated intermediate sprocket is in the
correct position:
• The white dot -arrow- on the intermediate sprocket must be
centered to the crankshaft.
AG. Volkswagen AG d
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♦ Make sure the coating on thehorisintermediate sprocket is not nte
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damaged. s aut ra
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♦ Due to the gear ratio, the white dot -arrow- does not go back
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to its original position after the engine is turned over.
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– Also install the new bolts in the sequence -1 to 8- hand-tight.
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– Tighten the balance shaft assembly bolts as follows:
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1. Pretighten the bolts in sequence -1 to 8- to 6 Nm.
t to the co
2. Tighten the bolts -5 and 7- to 13 Nm.
3. Turn the bolts -5 and 7- an additional 90° (1/4 turn) using a
rrectness of i
rigid wrench.
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4. Tighten the bolts -1 to 4, 6 and 8- to 20 Nm.

ProCarManuals.com
nform
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5. Turn the bolts -1 to 4, 6 and 8- an additional 90° (1/4 addi‐

tional turn) using a rigid wrench.
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– Secure the balance shaft with the Locking Tool - T10255- .
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Rotate the balance shaft if necessary. thi

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Tightening Sequence - Balance Shaft Module with Six Attach‐

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– Install the new bolts in the sequence -1 through 6- and tighten cted agen
Prote AG.
them by hand.
– Tighten the balance shaft module bolts in four stages as fol‐
lows:
– 1. Tight the bolts -1 through 6- to 6 Nm.
– 2. Tighten the bolts -1 through 4- to 20 Nm.
– 3. Tighten the bolts in sequence -5 and 6- to 13 Nm.

– 4. Tighten the bolts in sequence -1 through 6- turn an addi‐

tional 90° (1/4) turn using a ratchet.
• The locking tool pins must engage in the groove on the bal‐
ance shaft. n AG. Volkswagen A age G do
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– Carefully position the balance shaft spur gear on the balance

shaft while pressing the intermediate sprocket to the side
slightly.
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ProCarManuals.com
com
tio
Note
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♦ Make sure the threaded holes on the balance shaft are cen‐
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tered as much as possible in the oblong holes on the balance

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shaft spur gear.

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♦ If the oblong holes in the balance shaft spur gear cannot be
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aligned with the threaded holes in the cover, rotate the balance
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shaft spur gear the corresponding number of teeth and posi‐
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– Tighten the bolts for the balance shaft spur gear -arrows-.
– Remove the Locking Tool - T10255- .

The follow three steps must be performed at the same time (a

second technician is required):
– Press the intermediate gear -3- forcefully in the direction of
-arrow- into the splines of the crankshaft spur gear -2- and the
balance shaft spur gear -1- using a wooden block if necessary.
– Rotate the balance shaft spur gear counter-clockwise slightly.
– Tighten the new intermediate sprocket bolt:
– Remove the Crankshaft Stop - T10100- or the Crankshaft Stop
- T10050- .
Note
The intermediate sprocket must not have any backlash after in‐
stallation. This can be checked by pressing slightly by hand.

moval, while doing so pay attention to the following: AG. Volkswagen AG d
agen oes
lksw not
– Install the oil pan. Refer to d by
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⇒ “2.2 Oil Pan, Removing and Installing”, page 156 . orise nte
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– Install the toothed belt guard lower section: a c
ProCarManuals.com
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Cop py
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Prote AG.

2.4.3 Used Balance Shaft Assembly, Instal‐

ling
Conditions
• Crankshaft secured using the Crankshaft Stop - T10100- or
Caution
♦ If the intermediate sprocket bolt was loosened, the crank‐

shaft spur gear was replaced, or the crankshaft was re‐
moved, then a new intermediate sprocket with coating
must be installed and the hub -item 11- wagen AG. Volkswagen AG doe
⇒ Item 11 (page 154) including the bolt y V -item 12-
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⇒ Item 12 (page 154) and axial ribearing
sedb disc -item 13- ara
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⇒ Item 13 (page 154) must be ut
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o eo
backlash will not be correct. a ra
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♦ Installation procedure. Refer to

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⇒ “2.4.2 New Balance Shaft Assembly, Installing”,

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page 161 , New Balance Shaft Assembly, Installing
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Note
ProCarManuals.com
t to the co
♦ Proceed as follows if the used balance shaft assembly will be
installed again and neither the crankshaft spur gear was re‐
rrectne
placed nor the crankshaft was removed. Never loosen the
intermediate sprocket.
s
♦ Replace the bolts which have been tightened to torque.
s o
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– Secure the balance shaft with the Locking Tool - T10255- .

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Rotate the balance shaft if necessary.

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• The locking tool pins must engage in the groove on the bal‐
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– Check that the alignment sleeves for centering the balance

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shaft assembly on the cylinder block are present.
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– Position the balance shaft assembly on the cylinder block. rig ht
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• The intermediate sprocket must engage in the spur gear on cted agen
Prote AG.
the crankshaft when the balance shaft is locked.
• The intermediate sprocket must have slight noticeable back‐
lash.

– Also install the new bolts in the sequence -1 to 8- hand-tight.

– Tighten the balance shaft assembly bolts as follows:
1. Pretighten the bolts in sequence -1 to 8- to 6 Nm.
2. Tighten the bolts -5 and 7- to 13 Nm.
3. Turn the bolts -5 and 7- an additional 90° (1/4 turn) using a
rigid wrench.
4. Tighten the bolts -1 to 4, 6 and 8- to 20 Nm.
5. Turn the bolts -1 to 4, 6 and 8- an additional 90° (1/4 addi‐
tional turn) using a rigid wrench.
Tightening Sequence - Balance Shaft Module with Six Attach‐
ment Points
– Install the new bolts in sequence -1 through 6- and tighten

them by hand.
– Tighten the balance shaft module bolts in four stages as fol‐
lows:
ProCarManuals.com
– 1. Tight the bolts -1 through 6- to 6 Nm.

Volkswa
– 2. Tighten the bolts -1 sthrough
wage
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– 3. Tighten the bolts
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– 4. Tighten athe
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tional 90° (1/4) turn using a ratchet.
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– Remove the Crankshaft Stop - T10100- or the Crankshaft Stop

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- T10050- .
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– Install the toothed belt guard lower section:

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2.5 Spur Gear, Removing from Crankshaft

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⇒ “2.5.1 Spur Gear, Removing from Crankshaft”, page 166 .

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⇒ “2.5.2 New Spur Gear, Shrink-Fitting”, page 168 .
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2.5.1 Spur Gear, Removing from Crankshaft
c by lksw
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Prote AG.

♦ Commercially available hotplate
♦ Puller - Spur Gear - T10392- with

♦ Puller - Spur Gear - Press Piece - T10392/1-

♦ Digital Thermometer - VAS6519-
♦ Safety Gloves
– Remove the belt pulley side sealing flange. Refer to
⇒ “2.4 Sealing Flange, Removing and Installing, Belt Pulley
Side”, page 64 .
– Remove the balance shaft assembly. Refer to
page 159 .
– Insert the Puller - Spur Gear - Press Piece 1 - T10392/1- into
the crankshaft journal.
AG. Volkswagen AG d
agen oes
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ProCarManuals.com
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– Insert the Puller - Spur Gear - T10392-d by
into the holes in the ara
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spur gear and turn it clockwise thor in direction of -arrow-, then in‐ eo
stall the locating pin -A-. s au ra
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– Counterhold the crankshaft with a wrench -A-. Remove the

spur gear by installing the spindle with the wrench -B- or ratch‐
l purpos
et.
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2.5.2 New Spur Gear, Shrink-Fitting

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♦ Check the temperature
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with the Digital Thermometer - ac
VAS6519- when heating up the new spur gear.
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♦ When the temperature reaches 200 ℃ (392 °F), there are
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about four seconds to position the spur gear on the crankshaft.
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♦ A higher temperature increases the amount of time available
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for positioning (220 ℃ (428 °F) = approximately six seconds).
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♦ Make sure the crankshaft journal is clean.
es, in part or in w
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Caution
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Do not exceed the maximum temperature of 240 ºC (464 °F).
l purpos
Otherwise the spur gear will discolor and possibly become dis‐
torted.
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– Lay the entire surface of the new spur gear on a commercially
om
available hot plate and heat it to at least 200 ºC (392 °F), max‐
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– After the temperature is reached, remove the spur gear from

the pliers as shown.
Note
Make sure the splines on the spur gear are not damaged.

– Quickly slide the spur gear by onto the crankshaft journal all
the way by hand. Use the Seal Installer - Crankshaft/Camshaft
- 10-203- for assistance and do not tilt the gear.
– Let the spur gear cool a few minutes.
– Install the balance shaft assembly. Refer to
page 159 .
– Install the belt pulley side sealing flange. Refer to
⇒ “2.4 Sealing Flange, Removing and Installing, Belt Pulleywagen AG. Volkswagen AG does
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3 Lubrication System Components,

Engine Code CJAA
⇒ “3.1 Overview - Oil Pump and Oil Pan”, page 170
⇒ “3.3 Oil Pump, Removing and Installing”, page 175
Caution

damage, perform the following steps after the repair: AG. Volkswagen AG d
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3.1 Overview - Oil Pump and Oil Pan
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Oil spray nozzle and pressure relief valve. Refer to
⇒ Fig. ““Oil Spray Jet and Pressure Relief Valve”“ , page 172 .
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1 - Bolt
❑ 15 Nm
2 - Sealing Flange
❑ With gasket
❑ Must rest on the align‐
ment sleeves
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❑ Before installing, re‐
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clean cloth.
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3 - Chain Tensioner with Ten‐

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❑ 15 Nm
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5 - Funnel
6 - Guide Tube
7 - Alignment Sleeves
8 - O-Ring
❑ Replace
9 - Bolt
❑ 15 Nm
10 - Suction Line
❑ Clean the screen if there are debris
11 - Splash Wall
12 - Bolt
❑ 15 Nm
13 - Bolt
❑ 15 Nm
14 - Oil Pan
❑ Removing and installing. Refer to ⇒ “3.2 Oil Pan, Removing and Installing”, page 172 .
❑ Clean sealing surface before installing
❑ Install with silicone sealant D 176 404 A2
3. Lubrication System Components, Engine Code CJAA 171

15 - Oil Drain Plug

❑ 30 Nm lkswage es n
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17 - Oil Level Thermal Sensor - G266-
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19 - Oil Pump
❑ With pressure relief valve 12 bar (174.04 psi)
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❑ Replace if it moves with difficulty
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❑ Check if the oil pump moves with difficulty

❑ Before installing, check to be sure both alignment sleeves are present (for centering oil pump/cylinder
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❑ Removing and installing. Refer to ⇒ “3.3 Oil Pump, Removing and Installing”, page 175
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24 - Bolt
❑ 25 Nm
❑ Install without sealant
25 - Oil Spray Jet
❑ For the piston cooling. Refer to ⇒ Fig. ““Oil Spray Jet and Pressure Relief Valve”“ , page 172 .
Oil Spray Jet and Pressure Relief Valve

1- Bolt with Pressure Relief Valve, 27 Nm
2- Piston Cooling Oil Spray Jet
Note
When replacing the oil injector jet, pay attention to the correct
allocation for the pistons. Refer to Parts Catalog
3.2 Oil Pan, Removing and Installing

♦ Used Oil Collection and Extraction Unit - SMN372500-

♦ Silicone Sealant - D176404A2-

Removing
– Remove the noise insulation. Refer to ⇒ Rep. Gr. 50 .
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the engine and drain the engine oil.
Note
Follow all waste disposal regulations!
– Loosen the clamp -2-, lift the clip -1- and remove the connect‐
ing hose »cold side«.
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– Remove the bolt -arrow- and move the Engine Coolant Circu‐
lation Pump 2 - V178- to the side.
– Remove the bolt -arrow- on the charge air pipe on the »hot
side«.
– Disconnect the connector
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– Remove the
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the silicone sealant.

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– Position the oil pan immediately and gently tighten the bolts
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When installing the oil pan on a removed engine, make sure that
the oil pan is positioned flush with the crankshaft housing on the
flywheel side.
– Tighten the oil pan bolts in a diagonal sequence to 15 Nm.

– Tighten the oil pan/transmission bolts to 40 Nm.
Note
After installing the oil pan, allow the sealant to dry for approxi‐
mately 30 minutes. Only afterward may the engine oil be replen‐
ished.
Further assembly is performed in the reverse order of the remov‐

al.
3.3 Oil Pump, Removing and Installing

Removing
– Remove the oil pan and the splash wall. Refer to

– Remove the screw -2-.

– Pull off chain sprocket from oil pump shaft.
– Remove the bolts -1 and 3- and remove the oil pump.
Installing
– Insert the alignment sleeves at the top of the oil pump.
Insert the chain sprocket can only be positioned one way on the
oil pump shaft (flat side).
Component Nm
Chain sprocket to oil pump shaft 20 Nm + 90°.
Refer to 2).
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4 Oil Filter Bracket, Oil Cooler, Oil

Pressure and Oil Supply Line
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4. Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line 177
1 - Seal
❑ Replace
2 - Bolt
❑ 15 Nm + 1/4 (90 °) addi‐
tional turn
❑ Replace
❑ First, fasten upper left
and lower right bolts,
and then tighten all four
bolts in a diagonal se‐
quence
3 - Oil Filter Bracket
❑ Make sure there is
enough space to the
surrounding compo‐
nents
4 - Seal lkswage es n
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5 - Connection ss
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❑ 30 Nm
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6 - Oil Supply Line
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❑ 22 Nm
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❑ To turbocharger, engine
codes CBEA and CJAA
-item 4-
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⇒ Item 4 (page 271)
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❑ Oil Pressure and Oil Pressure Switch - F1- , Checking. Refer to
⇒ “4.4 Oil Pressure and Oil Pressure Switch F1 , Checking”, page 184 .
8 - Cover
❑ 25 Nm
9 - O-Ring
❑ Replace
10 - Oil Filter Element
❑ Follow the replacement intervals. Refer to ⇒ Maintenance ; Booklet 20.1 ; Procedure Descriptions .
11 - Seal
❑ Replace

❑ Coat with oil before assembly
❑ snaps into the tabs of the oil cooler
12 - Oil Cooler
❑ Make sure there is enough space to the surrounding components
❑ Oil Cooler, Checking for Leaks. Refer to ⇒ “1.11 Oil Cooler, Checking for Leaks”, page 214 .
13 - Seal
❑ Replace
14 - Sealing Plug
❑ 25 Nm
15 - Bolt
❑ 10 Nm
16 - Bracket
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– Remove the bolt -1- and remove the bracket.

– Loosen the clamp -2-, lift the clip -1- and remove the hose
»cold side« from the charge air cooler.
ProCarManuals.com
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– Remove the bolt -arrow- and move the Engine Coolant Circu‐
lation Pump 2 - V178- to the side.
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– Remove the oil supply line -3- on the oil filter bracket. Counter-
hold it if necessary with an open end wrench.
– Place the oil drip tray under the engine.
– Unscrew the bolts -arrows- and remove oil filter bracket.

Installing
Install in reverse order of removal while noting the following:
♦ Replace all seals, gaskets and O-rings.
♦ Oil filter bracket tightening specification. Refer to
page 177 .
♦ Charge air cooler tightening specifications. Refer to
page 290 .
♦ Fill the coolant. Refer to
4.3 Oil Supply Line to Turbocharger, Re‐

ProCarManuals.com

Removing:
⇒ “1.4 Engine Cover, Removing and Installing”,Gpage 90
. Volkswag.en nA AG do
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– Remove the air filter housing. Referyto Vol
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– Remove the charge air pipe -item 15- ⇒ Item 15 (page 291) .
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– Remove the rear clamp -arrow- from the cylinder head.

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– Loosen the union nuts on the oil filter bracket and turbocharger
with Union Nut Socket - T40055- .
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The Additional Numbered Steps Must Be Followed to Ensure the
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Oil Supply Line Is Installed Correctly:
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1. Set the union nuts of the oil supply line onto the connections.
2. Tighten the union nut on the oil filter bracket hand-tight.
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3. Tighten the union nut on the turbocharger hand-tight.
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4. Tighten the union nuts on the oil filter bracket first and then
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5. Mount the clamps and tighten the bolt and nut:
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• Tightening specification 10 Nm.

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Note
The connecting pipe between the exhaust manifold and inter‐

mediate sprocket must be replaced after removal.
– Install the connecting pipe between the exhaust manifold and

intake manifold -item 29- ⇒ Item 29 (page 273) .
– Install the warm air collector plate -item 2-
⇒ Item 2 (page 271) .
– Install the intake scoop -item 35- ⇒ Item 35 (page 273) .
– Install the charge air pipe -item 15- ⇒ Item 15 (page 291) .
– Install the intake hose between the Mass Airflow Sensor - G70-
and the intake scoop. Refer to
– Install the air filter housing. Refer to
4.4 Oil Pressure and Oil Pressure Switch -

F1- , Checking
⇒ “4.4.1 Oil Pressure Switch F1 , Checking”, page 184 .
⇒ “4.4.2 Oil Pressure, Checking”, page 184 .
4.4.1 Oil Pressure Switch - F1- , Checking

♦ Oil Pressure Gauge Kit - VAG1342-
♦ Voltage Tester VAS6839 - VAS6839- agen AG. Volkswagen AG do
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Test Conditions
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spec
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Test Sequence
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Functional check and servicing of the optical and acoustic oil

pressure gauge. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations and Voltage Tester VAS6839 - VAS6839- nf
ercia
“Function and Component Selection”.

orm
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– Disconnect the connector from the Oil Pressure Switch - F1- .

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– Connect the Voltage Tester VAS6839 - VAS6839- to Battery Prote AG.
- A- positive (+) terminal and the Oil Pressure Switch - F1-

using adapter cables from the Connector Test Set -
VAG1594D- .
• LED must not turn on.
If the LED turns on:
– Replace the Oil Pressure Switch - F1- :
If the LED does not turn on:
– Start the engine and slowly increase the speed:
• LED must light up at 0.55 to 0.85 bar (7.97 to 12.32 psi) pres‐
sure, otherwise replace the Oil Pressure Switch - F1- .
4.4.2 Oil Pressure, Checking


♦ Oil Pressure Gauge Kit - VAG1342-

♦ Wiring diagram. Refer to ⇒ Wiring diagrams, Troubleshooting
& Component locations.
Conditions
• The Oil Pressure Gauge Kit - VAG1342- is connected. Refer
to ⇒ “4.4.1 Oil Pressure Switch F1 , Checking”, page 184 , Oil
Pressure Switch - F1- , Checking.
Test Sequence
– Increase the speed further.
• At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil
pressure should be at least 2.0 bar (29 psi).
• At higher engine speeds, the oil pressure must not exceed 7.0
bar (101.52 psi)
If the specified value is not obtained:
– Replace the oil filter bracket if necessary. Refer to
page 177 , Overview - Oil Filter Bracket and Oil Cooler
Note
ProCarManuals.com
Also, mechanical damage, for example, bearing damage can also

be the cause of too low oil pressure.
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4. Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line
agen
Prote AG.
5 Special Tools

equipment required
♦ Oil Pressure Gauge Kit -
VAG1342-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set -
VAG1594D- supersedes
Connector Test Set - AG. Volkswagen AG d
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♦ T Bar And Socket - 10mm -
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♦ Used Oil Collection And Ex‐
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Prote AG.

♦ Locking Tool - T10255-
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♦ Seal Installer - Crankshaft/Camshaft
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♦ Commercially available hotplate
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♦ Not illustrated:
♦ Puller - Spur Gear - T10392-
♦ Puller - Spur Gear - Thrust Piece - T10392/1-
♦ Digital Thermometer - VAS6519-
♦ Elbow Assembly Tool - T10118-

19 – Cooling System
AG. Volkswagen AG d
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1 Cooling System Components
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♦ The cooling system is under pressure when the engine is
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vent eye injury and scalding.
spec
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♦ Reduce the pressure by covering the coolant reservoir cap
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with a cloth and carefully opening.
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Prote AG.
Note
♦ Secure all hose connections with hose clamps appropriate to

the model. Refer to the Parts Catalog.
♦ Hoses are secured with spring clips. If a repair is required only
use spring clips.
♦ When installing coolant hoses without tension, make sure they
do not come into contact with other components (observe the
marks on the coolant connections and hoses).
1. Cooling System Components 189

⇒ “1.1 Overview - Cooling System Components, Body Side”, page

190
⇒ “1.2 Cooling System Components, Engine-Side”, page 192
⇒ “1.3 Coolant Hose Connection Diagram”, page 197
⇒ “1.4 Air Shroud with Radiator Fan V7 and Radiator Fan 2 V177 ,
Removing and Installing”, page 202
⇒ “1.5 Radiator, Removing and Installing”, page 202
⇒ “1.6 Coolant Pump, Removing and Installing”, page 203
⇒ “1.7 Coolant Thermostat, Removing and Installing”, page 204
⇒ “1.8 4/2-Way Valve with Coolant Thermostat, Removing and
Installing”, page 205
⇒ “1.9 Coolant, Draining and Filling”, page 209
⇒ “1.10 Cooling System, Checking for Leaks”, page 212
⇒ “1.11 Oil Cooler, Checking for Leaks”, page 214
⇒ “1.12 Engine Preheater”, page 216 wage
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♦ Hose Clip Pliers - VAS6362- auth or
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1.1 Overview - Cooling System Components, Body Side
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190 Rep. Gr.19 - Cooling System

1 - Radiator
ling. Refer to
⇒ “1.5 Radiator, Remov‐
202 .
❑ Replace all of the cool‐
ant after replacing. Re‐ AG. Volkswagen AG d
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⇒ “1.9 Coolant, Draining ed by
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Coolant, Draining and aut ra
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2 - O-Ring
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3 - Upper Coolant Hose
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❑ With a quick-release
ole,
coupling
spec
t to the co
❑ Coolant Hose Connec‐
tion Diagram. Refer to
rrectne
⇒ “1.3 Coolant Hose
Connection Diagram”,
page 197 .
ProCarManuals.com
ss o
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4 - Cap
f inform
❑ Check the pressure
mer
valve in the cap. Refer to
atio
m
⇒ “1.10 Cooling System,

o
n
c
i
or
n
Checking for Leaks”,
thi
e
page 212 , Cooling Sys‐

t
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tem, Checking for Leaks
pr
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5 - Connector
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6 - Bolt
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❑ 3 Nm
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7 - Coolant Expansion Tank
❑ Cooling System, Checking for Leaks. Refer to
⇒ “1.10 Cooling System, Checking for Leaks”, page 212 .
8 - Lower Coolant Hose
❑ With a quick-release coupling
9 - Nut
❑ 5 Nm
10 - Bolt
❑ 5 Nm
11 - Radiator Fan 2 - V177-
12 - Radiator Fan - V7-
13 - Connector
14 - Air Shroud
⇒ “1.4 Air Shroud with Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing”,
page 202 .

1.2 Cooling System Components, Engine-

Side
⇒ “1.2.1 Overview - Cooling System Components, Intake Side,
without Engine Preheater”, page 192 .
⇒ “1.2.2 Overview - Cooling System Components, Intake Side,
with Engine Preheater”, page 193 .
⇒ “1.2.3 Overview - Cooling System Components, Transmission
Side”, page 194 .
1.2.1 Overview - Cooling System Compo‐

nents, Intake Side, without Engine Pre‐
heater
Refer to ⇒ “1.3 Coolant Hose Connection Diagram”, page 197 .
1 - Lower Expansion Tank

Coolant Hose
2 - Upper Expansion Tank
Coolant Hose
3 - Bolt
❑ 10 Nm
ProCarManuals.com
4 - Bleed Pipe
5 - Engine Coolant Tempera‐
ture Sensor - G62-
6 - Clip
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8- ut Cooler
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❑ Only on vehicles with
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9 - To the Upper Radiator

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10 - Engine Oil Cooler Coolant

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Supply Hose
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❑ On vehicles without a
transmission fluid cooler

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Transmission Fluid Cooler Re‐

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❑ On vehicles with a trans‐

mission fluid cooler
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12 - Engine Oil Cooler

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13 - Thermostat/4/2-Way
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❑ Starts to open: approximately 87 °C (188.6 °F)

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❑ Opening lift: minimum 7 mm
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❑ Coolant thermostat, removing and installing. Refer to Prote AG.
⇒ “1.7 Coolant Thermostat, Removing and Installing”, page 204 .

❑ 4/2-Way Valve with Thermostat, Removing and installing. Refer to
⇒ “1.8 4/2-Way Valve with Coolant Thermostat, eRemoving
n AG. Volkswand Installing”,
agen AG
page 205 .
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16 - Hose to Lower Radiator
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17 - Coolant Pump
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18 - Bolt ot p
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❑ 15 Nm
hole
spec
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t to the co
nents, Intake Side, with Engine Preheat‐
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Refer to ⇒ “1.3 Coolant Hose Connection Diagram”, page 197 .
nform
mercia
1 - Lower Expansion Tank
at
om
i
Coolant Hose
on
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or
2 - Upper Expansion Tank
his
ate
ProCarManuals.com
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Coolant Hose
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3 - Bolt
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❑ 10 Nm C py
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4 - Bleed Pipe
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5 - Engine Coolant Tempera‐
Prote AG.
ture Sensor - G62-

6 - Clip
7 - O-Ring
❑ Replace
8 - Transmission Fluid Cooler
Supply Hose
❑ On vehicles without a
transmission fluid cooler
❑ From the connection on
the cylinder block
Transmission Fluid Cooler Re‐
turn Coolant Hose
❑ On vehicles with a trans‐
mission fluid cooler
Return Hose
11 - To the Upper Radiator
12 - Bracket for Wiring Har‐
ness and Coolant Pipe
❑ Secured on the oil filter bracket -item 16- ⇒ Item 16 (page 179)
13 - Coolant Hose
❑ To the coolant pipe on the cylinder block

14 - Coolant Hoses
❑ For the transmission fluid cooler
❑ Only on vehicles with the DSG® transmission
15 - Coolant Pipe
❑ For the engine preheater
❑ Overview. Refer to ⇒ “1.12.1 Overview - Engine Preheater”, page 216 .
❑ Connection to the engine preheater and the engine oil cooler return line -item 10-
❑ Secured in the upper area on the bracket for the wiring harness and coolant pipe -item 16-
❑ Secured in the lower area on the charge air pipe with the engine preheater bracket
-Item 15- ⇒ Item 15 (page 291)
16 - Engine Preheater
❑ Removing and installing. Refer to ⇒ “1.12.2 Engine Preheater, Removing and Installing”, page 217 .
18 - Coolant Thermostat
❑ Starts to open: approximately 87 °C (188.6 °F)
ProCarManuals.com
❑ Stops opening: approximately 102 ℃ (215.6 °F)

❑ Opening lift: minimum 7 mm
❑ Coolant thermostat, removing and installing. Refer to
⇒ “1.7 Coolant Thermostat, Removing and Installing”,
. Volkswpage 204 .
agen AG
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❑ 4/2-Way Valve with Thermostat, Removing
yV
olk and installing. Refer stonot gu
⇒ “1.8 4/2-Way Valve with Coolant
ise Thermostat, Removing and Installing”,
d b ara page 205 .
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19 - Connection aut or
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20 - Bolt
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22 - Coolant Pump
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23 - Bolt
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❑ 15 Nm
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nents, Transmission Side

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ercia
Coolant Hose Connection Diagram. Refer to

⇒ “1.3 Coolant Hose Connection Diagram”, page 197 .
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1- Coolant
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2 - Coolant Hose to the Venti‐
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4 - Radiator Return Coolant
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5 - Heat Exchanger Coolant

Supply Hose
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6 - Heat Exchanger Coolant

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nents, Engine-Side, Engine Codes
CBDA, CBDB and CEGA
Coolant Hose Connection Diagram. Refer to
⇒ “1.3 Coolant Hose Connection Diagram”, page 197 .

1 - Grommet
❑ Not available separate‐
ly.
2 - Sleeve
❑ Not available separate‐
ly.
3 - 2.7 Nm
4 - 40 Nm
5 - Bracket
❑ For Engine Coolant Cir‐
culation Pump 2 - V178-
6 - Front Coolant Pipe
7 - O-Ring
❑ Replace AG. Volkswagen AG d
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10 - Engine Coolant Tempera‐ an
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11 - Clip
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12 - 9 Nm
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13 - 9 Nm
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14 - 9 Nm
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15 - Coolant Line
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16 - 9 Nm
17 - Seal
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❑ Replace
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❑ Replace
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Prote AG.
23 - Double Bolt, 9 Nm
❑
24 - 9 Nm
25 - Left Coolant Pipe
26 - 9 Nm
27 - 40 Nm
28 - 13 Nm
29 - Engine Coolant Circulation Pump 2 - V178-

1.3 Coolant Hose Connection Diagram

⇒ “1.3.1 Coolant Hose Connection Diagram, without Engine Pre‐
heater”, page 197
⇒ “1.3.2 Coolant Hose Connection Diagram, with Engine Pre‐
heater”, page 198
⇒ “1.3.4 Coolant Hose Connection Diagram, Vehicles with 4/2-
Way Valve, All Vehicles Except Jetta from MY 2011”, page 200
⇒ “1.3.5 Coolant Hose Connection Diagram, Vehicles with 4/2-
Way Valve, Only Jetta from MY 2011”, page 201
1.3.1 Coolant Hose Connection Diagram, without Engine Preheater

❑ With cap
❑ Pressure relief valve in‐
side cap, checking. Re‐
fer to
⇒ “1.10.2 Pressure Re‐
lief Valve in Cap, Check‐
ing”, page 214 .
2 - Cylinder Head/Cylinder
Block
ProCarManuals.com
❑ Change the coolant af‐

ter replacing
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3 - EGR Cooler yV
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❑ Change the coolant af‐ o
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❑ Overview. Refer to
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⇒ “3 EGR System”,
un
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page 398 .
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4 - Heater Core for the Heater
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7 - Radiator
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8 - Coolant Pump/Coolant
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Thermostat
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rrectness of i
Block
❑ Change the coolant af‐ l purpos
ter replacing
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ter replacing
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ProCarManuals.com
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Prote AG.
⇒ “1.12.1 Overview -
Engine Preheater”,
page 216 .
ling. Refer to
⇒ “1.12.2 Engine Pre‐
heater, Removing and Installing”, page 217 .
8 - Radiator
9 - Coolant Pump/Coolant Thermostat

1.3.3 Coolant Hose Connection Diagram, Engine Codes CBDA, CBDB and CE‐
GA

❑ With cap
fer to
ing”, page 214 .
2 - EGR Cooler
ter replacing
page 398 .
coupling
Block
ProCarManuals.com

ter replacing
6 - Engine Coolant Circulation
Pump 2 - V178-
7 - Upper Coolant Hose
coupling
AG. Volkswagen AG d
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1.3.4 Coolant Hose Connection Diagram, Vehicles with 4/2-Way Valve, All Vehi‐
cles Except Jetta from MY 2011
1 - Radiator
2 - Engine Coolant Circulation
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❑ Overview. Refer to ⇒ “3 EGR System”, page 398 .
9 - Auxiliary/Parking Heater
❑ Depending on the equipment
10 - Recirculation Pump - V55-
❑ Depending on the equipment
❑ With a quick-release coupling
❑ Only for vehicles with a DSG® transmission/automatic transmission

1.3.5 Coolant Hose Connection Diagram, Vehicles with 4/2-Way Valve, Only Jet‐
ta from MY 2011

❑ With cap
fer to
ing”, page 214 .
Block
ter replacing
3 - EGR Cooler
ter replacing
page 398 .
4 - Auxiliary/Parking Heater
ProCarManuals.com
❑ Depending on the
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❑ Depending on the
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11 - 4/2-Way Valve
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⇒ “1.8 4/2-Way Valve with Coolant Thermostat, Removing and Installing”, page 205 .
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1. Cooling System Components
1.4 Air Shroud with Radiator Fan - V7- and

Radiator Fan 2 - V177- , Removing and
Installing
Removing
– Remove the screws -upper arrows- from the air shroud.
– Remove the noise insulation. Refer to. ⇒
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– Disconnect the connector -1- and (if equipped) -2- and free up
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the wires.
– Remove the nuts -arrows- and remove the radiator fans.

Installing
Install in reverse order of removal.
1.5 Radiator, Removing and Installing


♦ Refractometer - T10007A-
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
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1.6 Coolant Pump, Removing and Installing
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– Remove the toothed belt. Refer to cted agen
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page 95 .
– Remove the bolts -1- of the coolant pump -2- and carefully take
out the coolant pump.
Installing:
• Replace the seals, gaskets and O-rings.

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1.7 Coolant Thermostat, Removing and In‐
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♦ Hex Ball Socket - T10058- Prote AG.

Removing:
– Remove the Throttle Valve Control Module - J338- . Refer to
page 331 , Overview - Intake Manifold with Attachments
– Remove the coolant hose from the connection.
– Loosen the bolts -4- from the connection -3- with T Bar And
Socket - 10mm - 3185- and remove using the Hex Ball Socket
- T10058- and remove the connection -3- with the coolant
thermostat -1-.
– Turn the thermostat -1- 1/4 turn (90°) to the left and remove it
from the connection -3-.
Removing:
• Replace the seals, gaskets and O-rings.

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block.
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– Secure the coolant hose to the connection.

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1.8 4/2-Way Valve with Coolant Thermo‐
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ProCarManuals.com
Prote AG.
stat, Removing and Installing

♦ Swivel Socket - Xzn 8 - T10445-
Removing
Note
The thermostat is inside the 4/2-way valve and cannot be re‐

placed separately.

– Remove the air filter housing with the mass airflow sensor and
connecting pipe. Refer to
page 338 .


Installing .
– Remove the crankcase ventilation hose -1- from the cylinder

head cover. To do this press the release button.
– Free up the vacuum hoses a-arrows-
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– Free up the wiring harnesses -arrows- and the connector -1-

on the bracket.
– Remove the bolts -2 and 5- and -arrows-.

– Free up the wires and hoses on the left air duct pipe using the
Pry Lever - 80-200- .
– Loosen the hose clamp -3- and remove the left air guide pipe.
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– Pull the coolant pipe out of the connection -C- on the 4/2-way
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– Loosen the hose clamp -2-.
– Disconnect the connector -1- from the Charge Air Pressure
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Sensor - G31- / Intake Air Temperature Sensor - G42- and
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– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.
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Gr. 27 ; Generator; Generator, Removing and Installing .
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– Remove the clip -2- using Pry Lever - 80-200- .
– Pull the oil dipstick tube upward out of the cylinder block and
move it to the side.
– Remove the coolant hoses from the connections
-A, B and D-.
– Remove the bolts -3- from the 4/2-way valve -2-.

– Pull the valve out of the cylinder block and then to the left in
order to remove the connection -C- from the coolant pipe.
Installing
Note
Replace the gaskets and seals.
Install in reverse order of removal while noting the following:

– First attach the 4/2-way valve with the connection -C- to the
coolant pipe and then install them in the cylinder block.
– Coat the new O-ring -1- with coolant.
– Tighten the bolts -3- to 15 Nm.
– Tighten the bolt on the coolant pipe behind the oil filter. Use
the Swivel Socket - Xzn 8 - T10445- . Tightening specification:
10 Nm.
ProCarManuals.com
1.9 Coolant, Draining and Filling

Special tools and workshop equipment required AG. Volkswagen AG d
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♦ Refractometer - T10007A- d by Vo gu
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♦ Drip Tray - VAG1306- utho eo
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♦ Hose Clip Pliers - VAS6362- s ce
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♦ Cooling System Charge Kit - VAS6096-

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♦ Cooling System Tester - Adapter - VAG1274/8-
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Note
♦ Drained coolant must be stored in a clean container for dis‐

posal or reuse.
♦ Follow all waste disposal regulations.
– Open the cap on the coolant expansion tank.

Note
– Place the Shop Crane - Drip Tray - VAS6208- under the en‐
gine.
– Remove the coolant hoses -1- on the Coolant Recirculation
Pump 2 - V178- -2-.
ProCarManuals.com
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– In addition, to drain the coolant from the engine, disconnect

the coolant hose at the oil cooler -arrow-.
Filling:
Caution
Only use distilled water for mixing with G12 plus plus. Using
distilled water provides optimum corrosion protection.
AG. Volkswagen AG d
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coolant and corrosion protection additives.
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♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy engine loads, particularly in
rrectne
countries with tropical climates.
ProCarManuals.com
♦ Freeze protection should be guaranteed to about -25 ℃ (-13
ss
°F) (in countries with arctic climates: to about -35 ℃ (-31 °F)).
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♦ The coolant concentration must not be reduced by adding wa‐
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ter even in warmer seasons and in warmer countries. The
atio
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coolant additive portion must be at least 40%.

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♦ The Refractometer - T10007- is recommended for determining

the current freeze protection density.
Recommended Mixture Ratios:
Frost Protection Freeze Protection Por‐ -G 12 plus-plus- . Refer to Distilled Water. Refer to 3) ,
to tion 3)
.
-25 °C (-13 °F) 40 % 3.2 liters (3.38 quarts) 4.8 liters (5.07 quarts)
-35 °C (-31 °F) 50 % 4.0 liters (4.22 quarts) 4.0 liters (4.22 quarts)
3) The coolant quantity can vary depending upon the vehicle equipment.

– Install the lower coolant hose and secure with the clamp
-arrow-.
– Connect the coolant hose to the oil cooler -arrow-.

With Cooling System Charge Kit - VAS6096- :
– Install the Cooling System Tester - Adapter - VAG1274/8- in agen
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Without Cooling System Charge Kit - VAS6096- :
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– Slowly fill the coolant up to the upper marking in the hatched
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– Seal the coolant expansion tank.
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– Start the engine and keep the engine speed at about 2000
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RPM for approximately three minutes.
– Let the engine run in idle until the Radiator Fan - V7- switches
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on.
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– Check the coolant level and fill if necessary.
• When engine is warm, coolant level must be at top marking
and when the engine is cold, it must be in the middle of the
hatched field.
1.10 Cooling System, Checking for Leaks

⇒ “1.10.1 Pressure Checking”, page 212
⇒ “1.10.2 Pressure Relief Valve in Cap, Checking”, page 214 .
1.10.1 Pressure Checking


♦ Cooling System Tester - VAG1274B-

Test Conditions
• Engine at operating temperature
Test Sequence
DANGER!

warm.

– Install the Cooling System Tester - Adapter - VAG1274/8- in
ProCarManuals.com
the coolant expansion tank.

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– Clamp the Adapter
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– Generate approximately 1 bar (14.5 psi) pressure using the

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♦ The existing pressure must be reduced before discon‐

necting the Cooling System Tester - VAG1274B- from the
connecting hose or the Adapter - VAG1274B/1- .
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♦ To do this, press the pressure release valve on the Cooling

System Tester - VAG1274B- until the pressure gauge dis‐
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1.10.2 Pressure Relief Valve in Cap, Checking
DANGER!

warm.

– 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 connecting hose provided.
– Generate a maximum pressure of 1.6 bar (23.2 psi) using the
ProCarManuals.com
hand pump on the Cooling System Tester - VAG1274B- .

• Pressure relief valve must not open yet.
If pressure relief valve opens prematurely:
– Replace the cap.
– Increase the pressure to above 1.6 bar (23.2 psi).
• Pressure relief valve must open.
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1.11 Oil Cooler, Checking for Leaks
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♦ Expansion Tank - 1K0 121 407 A or 6Q0 121 407 A or 1J0 121
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♦ Plug - 191 211 343-

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♦ Closure Cap - 1J0 121 324-

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Test Conditions
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Test Sequence
– Clamp off the coolant hoses from the oil cooler using Hose
Clamps - Up To 25mm - 3094- .
– Loosen the spring clamps -arrows- using the Hose Clip Pliers
- VAS6362- .
Note

– Mount the Closure Cap -5- on the rear connection on the oil
cooler -4-.
– Attach the Plug -2- to the coolant expansion tank vent con‐
nection -1-.
– Secure the coolant hose -3- on the oil cooler and on the cool‐
ant expansion tank.
ProCarManuals.com
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– Slowly fill the coolant up to the upper marking in the hatched

t to the co
area on the expansion tank.

– Position the Cooling System Tester - VAG1274B- with the
rrectness of i
Cooling System Tester - Adapter - VAG1274/8- on the coolant

expansion tank.
l purpos
– Generate a pressure of approximately 1.6 bar (23.2 psi) using

the hand pump on the Cooling System Tester - Adapter -
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– Watch the pressure decrease on the pressure gauge.

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– Replace the oil cooler. Refer to

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– Check the coolant level and fill if necessary. Refer to

1.12 Engine Preheater

⇒ “1.12.1 Overview - Engine Preheater”, page 216 .
⇒ “1.12.2 Engine Preheater, Removing and Installing”,
page 217 .
1.12.1 Overview - Engine Preheater
1 - Coolant Pipe for Engine

Preheater
❑ Secured in the upper
area on the bracket for
the wiring harness and
coolant pipe -item 13-
❑ Secured in the lower
area on the charge air AG. Volkswagen AG d
pipe with the engine pre‐ lksw
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2 - Coolant Hose from the Cyl‐
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inder Block Connection to the
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3 - Coolant Hose from the
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4 - Coolant Hose from the En‐
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the Engine Preheater
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5 - Locking Mechanism
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6 - External Power Supply

Connecting Cable
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7 - Left Air Grille

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– Air Grille, Removing and

ion in
installing. Refer to ⇒
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Body Exterior; Rep. Gr.

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63 ; Front Bumper Cov‐

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9 - Engine Preheater Prote
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10 - Engine Preheater Clamp
❑ Secured on the bracket
11 - Bolt
❑ 10 Nm
12 - Engine Preheater Bracket
13 - Bracket for Wiring Harness and Coolant Pipe
❑ Secured on the oil filter bracket -item 16- ⇒ Item 16 (page 179)
14 - Coolant Hose from the Engine Oil Cooler to the Engine Preheater Coolant Pipe
15 - Coolant Hose from the Engine Preheater to the Coolant Hose on the Cylinder Block

1.12.2 Engine Preheater, Removing and Instal‐

ling
Removing:
olkswagen AG
en AG. V
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. olkswag does
not
Gr. 50 ; Noise Insulation . ed
by
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– Drain the coolant. Refer to au
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⇒ “1.9 Coolant, Draining and Filling”, page 209 . ss c
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– Loosen the coolant hose clamp and remove the coolant hose
pt
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– Loosen the coolant hose clamp and remove the coolant hose
spec
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ProCarManuals.com
– Release the clamp -arrow B- and remove the Engine Preheat‐

er -arrow C- downward.
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Installing:
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2 Special Tools

equipment required
VAS6208-
VAS6362-
♦ Cooling System Charge Kit
- VAS6096- AG. Volkswagen AG d
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♦ Cooling System Tester b-y V ol not
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Adapter - VAG1274/8- rised
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3185-
5-50Nm - VAG1331-
VAS6208-
VAS6362-
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equipment required
3185-
♦ Refractometer - T10007 A-
5-50Nm - VAG1331-
VAS6208-
AG. Volkswagen AG d
VAS6340- ksw
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♦ Cooling System Tester -

VAG1274B-
Adapter - VAG1274/8-
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mm - 3094-
VAG1274B-
VAS6362-
VAS6208-
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♦ Swivel Socket - Xzn 8 - T10445-

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♦ Pry Lever - 80-200-


20 – Fuel Supply
1 Safety Precautions when Working on
Fuel Supply System n AG. Volkswagen AG
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♦ The fuel or fuel lines in fuel system can become very hot
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(danger of scalding)!
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♦ In addition, the fuel system is under pressure! Before

opening the system, place rags around the connection
ProCarManuals.com
area and release pressure by carefully loosening the con‐
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♦ Always wear protective eyewear, safety gloves and pro‐

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or
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♦ If fuel system components between the fuel tank and high
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system must be filled in order to bleed it. Refer to Cop py
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⇒ “3.9 Fuel System, Filling/Bleeding”, page 328 . (Run‐ gh ht
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Always Pay Attention to the following When Removing and In‐

stalling the Fuel Level Sensor - G- or the Fuel Pump - G23- (Fuel
Delivery Unit) From Full or Partially Filled Fuel Tanks.
♦ Before starting work, switch the exhaust extraction system on
and place an extraction hose close to the fuel tank installation
opening to extract fuel fumes. If no exhaust extraction system
is available, a radial fan (as long as motor 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.
1. Safety Precautions when Working on Fuel Supply System 223

2 Guidelines for Clean Working Condi‐

tions
When Working on the Fuel Supply/Injection System, Pay Careful
Attention to the following “7 rules” of Cleanliness:
♦ Thoroughly clean the connection points and the surrounding
area before loosening.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal opened components if the repair is not
performed immediately.
♦ Only install clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been loosely stored or unpackaged (for example, in
tool boxes etc.).
♦ Supplied transport and protective packaging and sealing cover
should only be removed immediately before installing.
♦ When the fuel system is open: avoid working with compressed
. Volkswagen AG
air if possible. Do not move the vehicle if possible. swa
gen AG does
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♦ In addition, do not let diesel fuel flow onto the coolant by
dhoses. ara
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If necessary, the hoses must be cleaned again immediately.
thor eo
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Replace corroded hoses. ss

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224 Rep. Gr.20 - Fuel Supply

3 Misfueling
⇒ “3.1 Step 1 (Engine Was Started with Incorrect Fuel)”,
page 225
⇒ “3.2 Step 2 (Engine Was Not Started with Incorrect Fuel)”, page
226
⇒ “3.3 Step 3 (Shavings in the Fuel Delivery Unit and Reservoir)”,
page 227
⇒ “3.4 Step 4 (No Shavings in the Fuel Delivery Unit and Reser‐
voir)”, page 228
⇒ “3.5 Step 5 (Shavings in the High Pressure Pump)”,
page 228
⇒ “3.6 Step 6 (No Shavings in the High Pressure Pump)”,
page 229
Caution
Fueling incorrectly can cause insufficient lubrication which can

lead to irreversible damage to the high pressure components,
especially the high pressure
wa gen Apump.
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dcaused
oes by seizing
and particle abrasionVolksshould be expected. These notparticles will
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♦ This information guides the reader through the individual pro‐

is n
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cedures like a flowchart.

ole,
spec
♦ The connector couplings must »audibly« engage when lock‐

t to the co
ing.
♦ Note the color coding when installing the connector coupling.
Refer to ⇒ page 245 !
rrectne
♦ Pull on the connector coupling to check for secure fit.

ss
♦ Disconnect the connector couplings. Refer to

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cial p
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⇒ “5 Connector Couplings, Disconnecting”, page 245 .

nform
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atio
m
Was the Engine Started with the Incorrect Fuel?

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⇒ “3.1 Step 1 (Engine Was Started with Incorrect Fuel)”, page

iv
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225 .
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3.1 Step 1 (Engine Was Started with Incor‐
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rect Fuel)
– Empty the fuel tank as much as possible through the filler neck
using the Fuel Extraction Unit - VAS5190- . Refer to
⇒ “4.4 Fuel Tank, Draining”, page 235 .
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Rear Bench Seat, Removing and Instal‐
ling .
– Remove the flange cover.
3. Misfueling 225
Note
Press the locking ring to release the fuel line.

AG. Volkswagen AG d
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If the battery is connected, make sure
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– Remove the fuel return line, which is blue or has a blue mark‐
wit
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ing, -1- from the fuel delivery unit. Disconnect the coupling.
h re
hole
Refer to
spec
es, in part or in w
t to the co
– Connect the Diesel Pressure Tester Kit - Adapter Set - Con‐
nection Hose 2 -VAS6551/5-2- to the fuel return line -1-.
rrectness of i
– Guide the free end of the Diesel Pressure Tester Kit - Adapter
Set - Connection Hose 2 -VAS6551/5-2- into a suitable con‐
l purpos
tainer.
– Connect the vehicle tester and perform the Guided Function
nf
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“Activate Fuel Pump (evacuate the fuel system)”.
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– Repeat this procedure as necessary until the fuel tank is com‐ C py
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Remove the Fuel Delivery Unit. Refer to Prote
cted AG.
agen
⇒ “4.6 Fuel Delivery Unit, Removing and Installing”, page 241 .
– Check the fuel tank for shavings.
– Empty the fuel delivery unit reservoir.
– Check the reservoir visually for large contaminants and shav‐
ings and on the screen.
Are There Any Shavings?
Yes. Refer to
⇒ “3.3 Step 3 (Shavings in the Fuel Delivery Unit and Reser‐
voir)”, page 227 .
No. Refer to
⇒ “3.4 Step 4 (No Shavings in the Fuel Delivery Unit and Res‐
ervoir)”, page 228 .
3.2 Step 2 (Engine Was Not Started with In‐

correct Fuel)
– Empty the fuel tank as much as possible through the filler neck
using the Fuel Extraction Unit - VAS5190- . Refer to
⇒ “4.4 Fuel Tank, Draining”, page 235 .
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Rear Bench Seat, Removing and Instal‐
ling .
– Fold the carpet to the side or forward if necessary.
– Remove the flange cover.

Note
Press the locking ring to release the fuel line.
AG. Volkswagen AG d
WARNING agen oes
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If the battery is connected, h ormake
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– Remove the fuel return line, which is blue or has a blue mark‐
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Refer to
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spec
– Connect the Diesel Pressure Tester Kit - Adapter Set - Con‐
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t to the co
nection Hose 2 -VAS6551/5-2- to the fuel return line -1-.
– Guide the free end of the Diesel Pressure Tester Kit - Adapter
Set - Connection Hose 2 -VAS6551/5-2- into a suitable con‐
rrectness of i
tainer.
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– Connect the Vehicle Diagnostic Tester and perform the Gui‐

ded Function “Activate Fuel Pump”.
ProCarManuals.com
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Note
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The fuel pump is now activated.

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– Repeat this procedure as necessary until the fuel tank is com‐

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– Fill the fuel tank with five liters (5.28 quarts) of diesel fuel.
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– Drain the fuel tank again completely as described above. cted agen
Prote AG.
– Reconnect the fuel return line (blue, or blue marking) -1-.

– Replace the fuel filter. Refer to ⇒ Maintenance ; Booklet 20.1 .
– Fuel the vehicle and perform a road test.
End
3.3 Step 3 (Shavings in the Fuel Delivery

Unit and Reservoir)
– Clean the fuel delivery unit and the fuel tank with the Suction
Pump - VAS5226- .
– Install the fuel delivery unit. Refer to
⇒ “4.6 Fuel Delivery Unit, Removing and Installing”,
page 241 .
– Fill the fuel tank with five liters (5.28 quarts) of diesel fuel.
– Drain the fuel tank again completely as described above.
3. Misfueling 227
– Replace the following high pressure components:

♦ High pressure pump. Refer to
page 325 .
♦ High pressure lines. Refer to
⇒ “3.4.1 High Pressure Lines, Installing”, page 318 .
♦ High pressure reservoir (Rail) including Fuel Pressure Regu‐
lator Valve - N276- and Fuel Pressure Sensor - G247- . Refer
to ⇒ “3.2 System Overview”, page 307
♦ Injector. Refer to
page 315
♦ Fuel return lines (oil overflow lines). Refer to
♦ Replace the fuel filter. Refer to
– Fuel the vehicle.
– Bleed the fuel system. Refer to
– Perform a road test.
End
ProCarManuals.com
3.4 Step 4 (No Shavings in the Fuel Delivery

Unit and Reservoir) lksw
agen
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– Fill the fuel tank with five liters (5.28 quarts)iseofd bdiesel fuel. ran
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– Drain the fuel tank again completely ass adescribed
ut above. or
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Caution an
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Removing the Fuel Metering Valve - N290- increases the risk ility
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ness.
spec
es, in part or in w
t to the co
– Carefully clean the high pressure pump near the Fuel Metering
Valve - N290- .
rrectness of i
– Disconnect from the valve.

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– Remove the bolts -arrows- and carefully remove the Fuel Me‐
tering Valve - N290- .
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– Inspect the Fuel Metering Valve - N290- and the high pressure
m
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page 228 .
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229 . Prote
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agen
3.5 Step 5 (Shavings in the High Pressure

Pump)
– Replace the following high pressure components:

♦ High pressure pump. Refer to

page 325 .
♦ High pressure lines. Refer to
♦ High pressure reservoir (Rail) including Fuel Pressure Regu‐
lator Valve - N276- and Fuel Pressure Sensor - G247- . Refer
to ⇒ “3.2 System Overview”, page 307
♦ Injector. Refer to
page 315
♦ Fuel return lines (oil overflow lines). Refer to
♦ Replace the fuel filter. Refer to
– Fuel the vehicle. agen
AG. Volkswagen AG d
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– Bleed the fuel system. Refer to d by V gu
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⇒ “3.9 Fuel System, Filling/Bleeding”, risepage 328 . nte
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– Perform a road test. ss c
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3.6 Step 6 (No Shavings in the High Pres‐
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Caution
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Make sure that the seals for the Fuel Metering Valve - N290-
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– Coat the lower seal for the Fuel Metering Valve - N290- with
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– Slide the valve into the high pressure pump by lightly twisting
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– Install both bolts -arrows- by hand.

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– First tighten the bolts to 3 Nm and then tighten them to 7 Nm.

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– Replace the fuel filter. Refer to ⇒ Maintenance ; Booklet 20.1 .
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– Bleed the fuel system. Refer to gh ht
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⇒ “3.9 Fuel System, Filling/Bleeding”, page 328 . cop Vo
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– Fuel the vehicle and perform a road test.
End
3. Misfueling 229
4 Fuel Supply System Components

⇒ “1 Safety Precautions when Working on Fuel Supply System”,
page 223
⇒ “2 Guidelines for Clean Working Conditions”, page 224
⇒ “4.1 General Information”, page 230
⇒ “4.2 Overview - Fuel Tank, All Vehicles Except Jetta from MY
2011”, page 231
⇒ “4.3 Overview - Fuel Tank, Jetta from MY 2011 Only”,
page 233
⇒ “4.4 Fuel Tank, Draining”, page 235
⇒ “4.5 Fuel Tank, Removing and Installing”, page 238
⇒ “4.6 Fuel Delivery Unit, Removing and Installing”, page 241
⇒ “4.7 Fuel Level Sensor G , Removing and Installing”,
page 243

ProCarManuals.com
Note

clamps.
♦ Always replace hose clamps with spring clamps. Refer to
Parts Catalog.
♦ Hose Clip Pliers - VAS6362- or theAG
Hose
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4.2 Overview - Fuel Tank, All Vehicles Ex‐

cept Jetta from MY 2011
DANGER!

Refer to
tions. Refer to
page 224 .
work.
1 - Cap
2 - Bolt
❑ 1.5 Nm
ProCarManuals.com
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⇒ “4.5 Fuel Tank, Re‐
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page 238 .
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❑ Support while removing

with the Engine and
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11 - Mount
❑ For the front muffler of the exhaust system -item 2- ⇒ Item 2 (page 381)
4. Fuel Supply System Components 231

12 - Seal
❑ Insert dry into the fuel tank opening
❑ Coat with fuel only when installing the flange
13 - Fuel Delivery Unit
❑ Note the installation position of the fuel delivery unit flange. Refer to
⇒ Fig. ““Fuel Delivery Unit Flange Installation Position”“ , page 232
❑ Fuel Delivery Unit, Removing and installing. Refer to
❑ With the Fuel Level Sensor - G-
❑ Fuel Level Sensor - G- , Removing and installing. Refer to
⇒ “4.7 Fuel Level Sensor G , Removing and Installing”, page 243 .
❑ With the Transfer Fuel Pump - G6-
❑ Transfer Fuel Pump - G6- , Checking. Refer to ⇒ “6.4 Transfer Fuel Pump G6 , Checking”, page 252 .
14 - Locking Ring
❑ 110 Nm
❑ Remove and install with the Wrench - Fuel Sending Unit - T10202- .
15 - Fuel Supply Line
❑ Black
ProCarManuals.com
❑ Attached to the side of the fuel tank

❑ To disconnect, press the release button on the connecting piece
❑ To fuel filter -item 1- ⇒ Item 1 (page 250)
16 - Fuel Return Line
❑ Blue
❑ Attached to the side of the fuel tank AG. Volkswagen AG d
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17 - Fuel Filler Door Unit

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❑ With rubber gasket

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The mark -3- on the flange points opposite the direction of travel.
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4.3 Overview - Fuel Tank, Jetta from MY

2011 Only
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Refer to ris
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❑ When replacing fuel

tank, set protective plate
on filler tube and rivet
clamp (holes on protec‐
tive plate must coincide
with holes on filler tube).
7 - Cable Guide
❑ For the ABS line
❑ Clipped to the shield
8 - Bolt
❑ 25 Nm
❑ Replace
9 - Fuel Tank
❑ Draining. Refer to
⇒ “4.4 Fuel Tank, Drain‐
ing”, page 235 .
ling. Refer to
⇒ “4.5 Fuel Tank, Re‐
moving and Installing”, page 238 .
❑ Support while removing with the Engine and Gearbox Jack - VAS6931- .

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❑ For the exhaust system -item 2- ⇒ Item 2 (page 383)
14 - Seal
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15 - Fuel Delivery Unit
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om
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AG.
ProCarManuals.com
16 - Locking Ring
❑ 110 Nm
❑ Remove and install with the Wrench - Fuel Sending Unit - T10202- .
❑ Black
❑ To fuel filter -item 1- ⇒ Item 1 (page 250)
❑ Blue
❑ From fuel filter -item 3- ⇒ Item 3 (page 250)
19 - Fuel Filler Door Unit
❑ With rubber gasket
❑ Removing and installing. Refer to ⇒ Body Exterior; Rep. Gr. 55 ; Fuel Filler Door Unit; Fuel Filler Door
Unit, Removing and Installing .
20 - Ventilation

Fuel Delivery Unit Flange Installation Position

The mark -3- on the flange points opposite the direction of travel.
1- Fuel Return Line (Blue)
2- Fuel Supply Line (Black)
3- Marking
Note
♦ The fuel delivery unit flange can only be installed in this posi‐
tion.
♦ Make sure the supply and return lines are still clipped to the
fuel tank after the fuel delivery unit flange has been installed.
4.4 Fuel Tank, Draining

⇒ “4.4.1 Fuel Tank, Draining When More than 3/4 Full”,
page 235 gen AG
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Caution
Prote AG.
Secure the Fuel Extraction Unit - VAS5190- ground wire to a

bare area of the chassis.

– Remove the cone piece -2- from the shaft piece -1- on the Fuel
Extraction Unit - VAS5190- .
– Using insulating tape, apply a mark on the hose -arrow- -a- =
1,180 mm from the end of the suction hose.
– Open fuel tank flap and remove fuel tank cap.

– Attach the shaft piece -1- from the Fuel Extraction Unit -
VAS5190- to the fuel tank filler tube.
– Slide the suction hose as far into fuel tank until the mark ap‐
plied earlier -arrow- stands on shaft piece.
ProCarManuals.com
Note
There is a ball valve -2- located at the lower end of the filler neck
in the fuel tank -1- that must not be damaged by the suction hose
-3-. Therefore slide in hose only up to the marking -arrow- applied
earlier.
– Empty the fuel tank as much as possible

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⇒ “4.4.2 Fuel Tank, Draining When Less Than 3/4 Full”, page
spec
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4.4.2 Fuel Tank, Draining When Less Than 3/

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Rep. Gr.20 - Fuel Supply Prote AG.
olkswagen AG
ag 2010 ➤ , Jetta 2005 en AG. V
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page 224 .
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– Remove the bench seat. Refer to ⇒ Body Interior; Rep. Gr.

72 ; Rear Seats; Rear Bench Seat, Removing and Installing .
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– Unclip the cover -1- for the fuel delivery unit. The arrow -2-
n in
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points in the direction of travel.

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♦ Wrap a cloth around the wiring connections before loos‐
ening hose connections. Then release pressure by care‐
fully pulling off the line.
– Disconnect -1-, the black supply line -2- and the blue return
line -3-.
Note
Press the locking ring to release the fuel lines.
– Open locking ring using Wrench - Fuel Sending Unit -
T10202- .
– Slightly lift out the fuel delivery unit flange.
– Insert the suction hose from the Fuel Extraction Unit -
VAS5190- as far as possible into the fuel tank and extract the
fuel.
If the fuel tank only needed to be emptied, install the fuel delivery
unit again. Refer to

4.5 Fuel Tank, Removing and

swa
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Removing:
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Fuel tank may be a maximum of 1/4 full.
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If necessary, empty the fuel tank using the Fuel Extraction Unit -
AG.
VAG5190- . Refer to ⇒ “4.4 Fuel Tank, Draining”, page 235 .
Procedure
Caution

A- is disconnected:

– Clean the surrounding area around the fuel filler tube.
– Open fuel tank flap and remove fuel tank cap.
– Remove the bolts from the fuel filler door unit and then remove
the fuel filler door unit. Refer to ⇒ Body Exterior; Rep. Gr. 55 ;
Fuel Filler Door Unit .
– Remove the right rear wheel housing liner. Refer to ⇒ Body

– Remove the bolts -1- for the fuel filler neck.

– Disengage the ABS speed sensor wire -2- on the filler neck
bracket.
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– Disconnect -1- from the fuel delivery unit flange.
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– Remove the center muffler and exhaust pipe. Refer to

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⇒ “1.7 Overview - Muffler”, page 381 .
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Note
The front and rear muffler may need to be removed beforehand.

rrectness of i
Refer to
⇒ “1.8 Exhaust System, Disconnecting and Connecting”,
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page 384 .
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– Disconnect the black supply line -1- and the blue return line
-2- between the fuel tank and the assembly.
Note
Note
A second technician is required for the remainder of the proce‐

dure to help support the fuel tank. agen
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– Remove the mounting strap and bolts -arrows-. Support ththe
or eo
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– Slowly lower fuel tank.
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ProCarManuals.com
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The fuel filler neck must be “guided out” between the body and
es, in part or in w
rear axle. To do so, lift the fuel tank down from the Engine and
t to the co
Gearbox Jack - VAS6931- with the help of a second technician.
Installing:
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– With the help of a second technician, guide the fuel filler neck
between rear axle and body. Then place the fuel tank on the
Engine and Gearbox Jack - VAS6931- .
– Lift the fuel tank slowly up to the installation position and se‐
cure it with new bolts -arrows-.
• Tightening specification -item 7- ⇒ Item 7 (page 231) /
lowing:
• Tightening Specifications: ReferVoto
⇒ “4.2 Overview - Fuel AG. lkswagen G d
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233 , Overview - Fuel Tank - Jetta from MY 2011 Only
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• Check the fuel tank/body ground connection on the filler neck
ProCarManuals.com
for secure fit -item 3- ⇒ Item 3 (page 231) / -item 3-

⇒ Item 3 (page 233) .
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• Make sure the fuel lines are still attached to the fuel tank after
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4.6 Fuel Delivery Unit, Removing and In‐

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work.

Removing:
Conditions
• Fuel tank may be a maximum of 1/2 full.

Note
If necessary, empty the fuel tank using the Fuel Extraction Unit -
VAG5190- . Refer to ⇒ “4.4 Fuel Tank, Draining”, page 235 .
Procedure
Caution

A- is disconnected:

ProCarManuals.com
– Unclip the cover -1- for the fuel delivery unit.

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ening hose connections. Then release pressure by care‐

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– Disconnect -1-, the black supply line -2- and the blue return
line -3-.
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– Open locking ring using Wrench - Fuel Sending Unit -

T10202- .
– Pull the fuel delivery unit and gasket out of the fuel tank open‐
ing.
Note
♦ If the fuel delivery unit is to be replaced then drain old delivery

unit before disposal.
♦ Follow all waste disposal regulations.
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hole
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• Coat the seal with fuel only for installing the fuel delivery unit.
t to the co
ProCarManuals.com
• Note the installation position of the fuel delivery unit flange:

• For the Jetta from MY 2005 through 2010, Jetta SportWagen
rrectness of i
(US)/Jetta Wagon (Canada) for MY 2009 and Jetta SportWa‐
l purpos
gen (US)/Golf Wagon (Canada) from MY 2010. Refer to

⇒ Fig. ““Fuel Delivery Unit Flange Installation Position”“ , page
232 .
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• For Jetta from MY 2011. Refer to orm

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4.7 Fuel Level Sensor - G- , Removing and

Installing
DANGER!

Refer to
tions. Refer to
page 224 .
work.

Removing:
– Remove the fuel delivery unit. Refer to
page 241 .
– Move the Fuel Level Sensor - G- slightly to the side and up‐
ward at the same time.
– Push the tabs -arrows- to the side if it is not possible to release

the sensor.
– Write down the cable color coding for reinstallation.
– Disconnect the connectors -1 through 3-.
ProCarManuals.com
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– Pay attention to the color coding.

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– Pull on the connectors to make sure they are secure.

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– Insert the Fuel Level Sensor - G- in the guide on the fuel de‐
livery unit and push down until it engages.
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– Install the fuel delivery unit. Refer to

ion in

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5 Connector Couplings, Disconnecting

♦ Lever - Fuel Line - T10468-
Connector Coupling Allocation
Note
♦ 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.
♦ The connector couplings must »audibly« engage when lock‐
ing.
♦ Pull on the connector coupling to check for secure fit.
Connector Coupling Color Coding on the Connector

Coupling
Fuel supply Black
Fuel Return Line Blue
Ventilation White, beige
ProCarManuals.com
Vacuum Green
WARNING
The fuel supply line is under pressure. Wear protective eye‐

wear and protective clothing to avoid injury and contact with
skin. Place a cleaning cloth
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spec
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5. Connector Couplings, Disconnecting 245

Continuation for all separating points on the fuel system

– Push the connector coupling -1- in the direction of -arrow A-.
– Press the release buttons and hold it down.
– Disconnect the connector coupling -1- from the fuel line -2- in
the direction of -arrow B-.
Follow the color coding during installation. Refer to ⇒ page 245
The connector couplings must »audibly« engage when locking.
– Pull on the connector coupling to check for secure fit.

Version 2
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Version 3
Coupling with button on the front -arrow-
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– Press the release button -arrow- and disconnect couplings.
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Version 6
Opening
– Press the connector coupling -1- in the direction of -arrow- and
hold it down.
– Press the release buttons -arrows- and disconnect coupling.
Note the color coding when installing. Refer to ⇒ page 245 .
5. Connector Couplings, Disconnecting 247

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6 Fuel Supply System, Servicing

⇒ “6.2 Overview - Fuel Filter”, page 249
⇒ “6.3 Fuel Filter, Removing and Installing”, page 251
⇒ “6.4 Transfer Fuel Pump G6 , Checking”, page 252
⇒ “6.5 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Checking”,
page 257
⇒ “6.6 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing
and Installing”, page 259
Note

clamps.
♦ Hose Clip Pliers - VAS6362- or the Hose Clip Pliers - agen
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page 224 .
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Fuel Filter, Removing and installing. Refer to

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6. Fuel Supply System, Servicing 249


❑ Black
❑ From Fuel Tank- All Ve‐
hicles Except Jetta from
MY 2011 -item 15-
❑ From Fuel Tank - Jetta
from MY 2011 Only
-item 17-
2 - Screw
❑ 9 Nm
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❑ Check for secure fit horis
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❑ To Fuel Tank - Jetta
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4 - Plug
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❑ 5 Nm
❑ For water extraction
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❑ Remove and extract ap‐
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proximately 100 cm3 of

fluid with Suction Pump
- VAS5226-
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❑ Blue or with blue marking
❑ -item 4- ⇒ Item 4 (page 312)
8 - Fuel Filter Upper Section
9 - Fuel Filter Insert
❑ Note the change intervals. Refer to ⇒ Maintenance Intervals; Rep. Gr. 03
10 - Fuel Filter Lower Section
11 - Bolt
❑ 8 Nm
12 - Seal
❑ Replace

6.3 Fuel Filter, Removing and Installing
DANGER!

Refer to
System”, page 223 . AG. Volkswagen AG d
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ProCarManuals.com
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A - Fuel Supply Line, Black

B - Fuel Return Line, Blue or with Blue Marking
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• Bolt and nut tightening specification -item 11-
⇒ Item 11 (page 250) .
white marking).
• Clip the fuel hoses back into the retainers.

6.4 Transfer Fuel Pump - G6- , Checking

⇒ “6.4.1 Fuel Delivery Rate, Checking”, page 252 .
⇒ “6.4.2 Power Supply, Checking”, page 253
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♦ Vehicle Diagnostic Tester
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Test Conditions:
• The battery voltage must be at least 12.0V.
• The fuses must be OK.
Test Sequence
– Disconnect -1- from the Auxiliary Fuel Pump - V393- .

– Disconnect the fuel supply line (black) -A- to the fuel tank.
– Connect the line from the Pressure Tester Kit - VAS6550- on
the fuel supply line -A- to the fuel tank.
– Guide the open end of the hose from the Pressure Tester Kit
- VAS6550- into the measuring container.
– Open the shut-off valves in front of and behind the pressure
gauge in the flow direction and connect the lower shut-off
valve.
– Connect the Vehicle Diagnostic Tester -1- as follows:

– Connect diagnostic cable -2- to Data Link Connector (DLC) in
driver footwell.
– Switch the ignition on.
– Perform “Guided Functions, check electric fuel pump(s)”. Re‐
fer to Vehicle Diagnostic Tester .
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The fuel pump now runs for 30 seconds.
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– Check the fuel pump voltage supply. Refer to
⇒ “6.4.2 Power Supply, Checking”, page 253 . Check the cur‐
rrectness of i
rent draw. Refer to
⇒ “6.4.3 Current Draw, Checking”, page 255 .
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6.4.2 Power Supply, Checking

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The Transfer Fuel Pump - G6- runs very quietly.
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ProCarManuals.com
– Switch off the ignition.

If the Transfer Fuel Pump - G6- does not run:
– Connect the Vehicle Diagnostic Tester - Test Adapter - 5 Pin

- VAS5565- between the connector and the flange.
– Connect the Analog/Digital Multimeter - FLU83III- to the test
contacts -1- and -5- on the Adapter .


driver footwell.
fer to Vehicle Diagnostic Tester .
Note
The Transfer Fuel Pump - G6- is now activated for 60 seconds.
– Read the voltage value on the Analog/Digital Multimeter .

• Specified value: approximately battery voltage
If there is no voltage:
– Check the Fuel Pump Relay - J17- activation and check the
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– Replace the fuel delivery unit if the Fuel Pump Relay - J17- is
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page 241 .
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6.4.3 Current Draw, Checking

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♦ Pressure Tester Kit - VAS6551-

Test Conditions
• Fuel temperature in the fuel tank above 10 °C (50 °F).
Note
The battery voltage and the temperature of the diesel fuel strongly
influence the current draw of the fuel pump. Make sure the battery
voltage is at least 12 Volts and the temperature of the diesel fuel
inside the fuel tank is not at the freezing point.
Test Sequence
ProCarManuals.com
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– Connect the Vehicle Diagnostic Tester - Test Adapter - 5 Pin

- VAS5565- between the connector and the flange.
– Connect the current probe -A- to the red cable with the word
“current probe” on the Vehicle Diagnostic Tester - Test Adapt‐
er - 5 Pin - VAS5565- .
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ProCarManuals.com
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The Auxiliary Fuel Pump - V393- is now activated for 60 seconds.
– Read the current draw on the Analog/Digital Multimeter .

Specified Value:
• minimum 5.5 amp
• maximum 7.5 amp
If the current draw is outside of the specified value:
– Replace the fuel delivery unit if the Auxiliary Fuel Pump - V393-
is faulty. Refer to
page 241 .
6.5 Auxiliary Fuel Pump - V393- (Inline Fuel

Pump), Checking

♦ Diesel Pressure Tester Kit - VAS6551-

Test Conditions:
• Battery voltage at least 12.5 V.
• The fuel filter is OK.
• Fuel tank is minimum 1/2 full.
WARNING
♦ Follow the guidelines and instructions for clean working

conditions when working on the fuel system. Refer to
page 224 .
♦ Always follow these guidelines and instructions for clean
working conditions before and during work.
♦ Before opening the fuel system, lay a clean cloth around en AG. V
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Note
♦ The Diesel Pressure Tester Kit - VAS6551- is switched on in

the fuel supply line.
♦ Illustration shows VAG1318, use Diesel Pressure Tester Kit -
VAS6551- .
– Connect the Vehicle Diagnostic Tester and perform the Gui‐

ded Function “Check electrical fuel pumps”.
Note
The fuel pump is now activated for 30 seconds.
– Let the fuel pumps run until the highest fuel pressure is
reached.
• Specified value: minimum 3.5 bar (50.76 psi) swage
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Note
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6.6 Auxiliary Fuel Pump - V393- (Inline Fuel

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and remove the fuel supply line -item 6- ⇒ Item 6 (page 250)
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– Disconnect the connector from the Fuel Temperature Sensor

- G81- -arrow-.
VAS6362- and disconnect the fuel supply line at the high
pressure fuel pump.

– Remove the bolts -arrows- and remove the Auxiliary Fuel

Pump - V393- .
Installing:
white marking).
• Clip the fuel and coolant hoses back into the holders.
• Bolt for Exhaust Pressure Sensor 2 - G451- bracket: 8 Nm.
• Bolts for the Auxiliary Fuel Pump - V393- : 20 Nm.
AG. Volkswagen AG d
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7 Electronic Engine Output Control

(EPC)
⇒ “7.1 EPC System Function”, page 262
⇒ “7.2 Overview - Accelerator Pedal Module”, page 262
⇒ “7.3 Accelerator Pedal Module, Removing and Installing”, page
263
7.1 EPC System Function

For EPC, the throttle valve is not operated by a cable from the
accelerator pedal. There is no mechanical connection between
the gas pedal and the throttle valve.
The position of the accelerator pedal is transmitted to the Engine
Control Module - J623- via two accelerator pedal position sensors
(adjustable resistances, accommodated in one housing), that are
connected to the accelerator pedal.
The position of the accelerator pedal (driver controlled) is a main
input for the Engine Control Module - J623- .
Throttle valve operation occurs via an electric motor (throttle valve
actuator) in the Throttle Valve Control Module - GX3- and this
occurs over the entire engine speed and engine load spectrum.
ProCarManuals.com
The throttle valve is operated by the throttle drive according to the

instructions of the Engine Control Module - J623- .
With the engine stopped and the ignition switched on, the Engine
Control Module - J623- activates the throttle valve actuator ac‐
cording to the specifications from the Throttle Position Sensor -
G69- . This means, if the accelerator pedal is depressed half gway,en AG. V
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the throttle drive opens the throttle valve to the same degree.
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throttle valve is then opened approximately half way.ed by ara
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or
With engine running (under load) the EngineauControl
th Module - or
ac
J623- can open and close the throttle valve independently of the
ss
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Throttle Position Sensor - G69- .

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This means, for example, that the throttle valve could be fully
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opened even though the accelerator pedal has only been de‐
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pressed half way. This has the advantage of preventing torque

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losses at the throttle valve.

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After evaluating the torque requirements of the various compo‐

es, in part or in w
nents (such as the A/C system, automatic transmission, ABS/

t to the co
ESP, etc.), the Engine Control Module - J623- calculates the op‐
timal throttle valve opening angle for the current situation.
rrectness of i
Aside from that, it results in clearly better pollutant output and

consumption values under certain load conditions.
l purpos
“E-Gas” is a system containing all components that contribute to

recognizing, controlling and monitoring the position of the throttle
nform
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valve, for example the Throttle Position Sensor - G69- , Throttle

Valve Control Module - GX3- , EPC Indicator Lamp - K132- , En‐
m
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gine Control Module - J623- .

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7.2 Overview - Accelerator Pedal Module

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1 - Connector
❑ Black 6-pin
2 - Accelerator Pedal Module
❑ With Accelerator Pedal
Position Sensor - G79-
and Accelerator Pedal
Position Sensor 2 -
G185-
❑ Not adjustable
❑ -A- Openings for Re‐
lease Tool
ling. Refer to
⇒ “7.3 Accelerator Ped‐
al Module, Removing
and Installing”,
page 263 .
❑ Checking. Refer to Ve‐
hicle Diagnostic Tester .
3 - Bolt
❑ 9 Nm
4 - Cap
ProCarManuals.com
AG. Volkswagen AG d
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7.3 Accelerator Pedal Module, Removing

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♦ Accelerator Pedal Module Release Tool - T10238-

ole,
spec
Removing:
t to the co
– Remove the steering column cover -arrows-.

– Pry out the cap -item 4- ⇒ Item 4 (page 263) using a screw‐
rrectne
driver.
– Remove the bolt -item 3- ⇒ Item 3 (page 263) .
ss o
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– Slide the Accelerator Pedal Module Release Tool - T10238-

inform
into the designated openings for it until it stops and remove

mer
accelerator pedal module.

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7. Electronic Engine Output Control (EPC) 263

AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta
rise 2005 ➤ , Jetta 2011 ➤
d b ara
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4-Cylinder Diesel Engine (2.0L Engine, Common
autho
Rail) - Edition 04.2015 eo
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– Disconnect the connector from the accelerator pedal module.
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Installing:
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– Connect the connector -2- to the accelerator pedal module
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-5- and push the rubber grommet -1- onto the connector again.
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– Press the accelerator pedal module onto the retaining pins
spec
-6-.
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– Insert centering pin -7- into hole on vehicle floor.
rrectness of i
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– Secure the accelerator pedal module with the bolt -3-.
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– Install the cap -4-.
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Prote AG.
– Install the steering column cover -arrows-.

8 Special Tools

equipment required
♦ Wrench - Fuel Sending Unit
- T10202-
40-200Nm - VAG1332-
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♦ Fuel Siphoning Device - Volksw not
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VAS5190A- se
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♦ Accelerator Pedal Module Release Tool - T10238-

♦ Lever - Fuel Line - T10468-
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♦ Torque Wrench 1331 5-50Nm - VAG1331- ss
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♦ Engine/Gearbox Jack - VAG1383A- rrectness o

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♦ Vehicle Diagnosis System - VAS5051B-


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♦ Pickup Clamp - VAG1526B/2-
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♦ Diesel Pressure Tester Kit - VAS6551-
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♦ Diesel Pressure Tester Kit - Adapter Set - Connection Hose 2

- VAS6551/5-2-
♦ Suction Pump - VAS5226-

21 – Turbocharger, Supercharger
Charge Air System And Turbocharg‐
er
WARNING n AG. Volkswagen AG do

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When doing any assembly work,oespecially in the engine com‐
ran
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partment, pay attention to theau following due to the limited
th or
ac
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If testing equipment is required during a road test, note the fol‐
rrectness of i
lowing:
ProCarManuals.com
l purpos
♦ The testing equipment must always be secured to the rear seat

and operated by a second technician from this location.
nform
ercia
If the vehicle is involved in a collision while testing equipment is

operated from the front passenger seat, the person sitting in that
m
a
seat could be seriously injured when the airbag deploys.
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268 Rep. Gr.21 - Turbocharger, Supercharger


tions
When Working on the Charge Air System and Turbocharger,
Carefully Follow the “7 rules” for Clean Working Conditions:
♦ Thoroughly clean the connection points and the surrounding
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths.
tool boxes etc.).
♦ Transport and protective packaging and sealing caps are to
be removed only immediately prior to installation.
♦ During repairs, clean oil from connections and hose ends.
air if possible. Do not move the vehicle if possible.
ProCarManuals.com
When working on the turbocharger, Acarefully

G. Volkswagobserve
en AG the follow‐
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ing rules for clean working oconditions: does
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2. Guidelines for Clean Working Conditions 269

3 Turbocharger
Note
♦ Various hose connections are secured.

♦ The charge air system must be properly sealed.
clamps.
♦ Fill with engine oil before installing the turbocharger oil supply
line on the connections
♦ After installing the turbocharger, let engine idle for approxi‐
mately one minute to ensure adequate oil supply to the turbo‐
charger.
Caution
♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to
⇒ “1 Safety Precautions when Working on Charge Air
System And Turbocharger”, page 268 .
ProCarManuals.com

tions. Refer to
page 269 .
work.
⇒ “3.1 Overview - Turbocharger with Exhaust Manifold and At‐

tachments”, page 270 en AG. V
olkswagen AG
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⇒ “3.2 Turbocharger withbExhaust
yV
ol Manifold, Removing and
ot gIn‐
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stalling, Engine Codes
ris CBEA, CJAA”, page 276
ed ran
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⇒ “3.3 Turbocharger au with Exhaust Manifold, Removing and In‐ ra
c
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stalling, Engine Codes CBDA, CBDB, CEGA”, page 279
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⇒ “3.4 Vacuum Diaphragm with Charge Air Pressure Actuator

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Position Sensor G581 , Replacing”, page 282

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3.1 Overview - Turbocharger with Exhaust

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Manifold and Attachments

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Caution

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page 269 .
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270
AG.
Rep. Gr.21 - Turbocharger, Supercharger
4-Cylinder
olksw
Diesel Engine (2.0L Engine, Common Rail) - Edition 04.2015
AG. V agen AG
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⇒ “3.1.1 Engine db
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CBEA, CJAA”, page 271 gu
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⇒ “3.1.2 uEngine
tho Codes CBDA, CBDB and CEGA”, page e o 274
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3.1.1 Engine Codes CBEA, CJAA
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Overview - Particulate Filter with NOx Reduction Catalytic Con‐
h re
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verter. Refer to
spec
⇒ “1.2 Overview - Particulate Filter with NOx Reduction Catalytic
es, in part or in w
t to the co
Converter”, page 360 .
rrectness of i
1 - Bolt
l purpos
❑ 8 Nm
2 - Warm Air Collector Plate
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❑ To the warm air intake
rm
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connecting hose on the
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air filter -item 12-
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3 - Bolt
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❑ 10 Nm
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4 - Oil Supply Line
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gles of the oil supply line
❑ From oil filter bracket
-item 6-
ling. Refer to
Turbocharger, Remov‐
182 .
❑ Before installing, check
the oil supply line for
clear passage
❑ Fill with engine oil be‐
fore installing the turbo‐
charger oil supply line
on the connections
5 - Vacuum Hose
❑ Check for secure fit and
kink free routing
❑ To the Wastegate By‐
pass Regulator Valve - N75-
❑ Connection diagram for vacuum hoses. Refer to
⇒ “4.5 Vacuum Hose Connection Diagram”, page 295 .
6 - Vacuum Diaphragm
❑ With the Charge Air Pressure Actuator Position Sensor - G581-
⇒ “3.4 Vacuum Diaphragm with Charge Air Pressure Actuator Position Sensor G581 , Replacing”, page
282 .
❑ Unit with turbocharger and exhaust manifold (cannot be replaced separately)
3. Turbocharger 271
7 - Heat Shield
8 - Heat Shield
9 - Bracket
10 - Seal n AG. Volkswagen AG do
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❑ Replace byV ua
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11 - Clamp auth or
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❑ 7 Nm
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❑ Replace
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❑ Note the installation position Refer to
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⇒ “1.2 Overview - Particulate Filter with NOx Reduction Catalytic Converter”, page 360 .
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12 - To the Particulate Filter
h re
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❑ Refer to ⇒ “1.2 Overview - Particulate Filter with NOx Reduction Catalytic Converter”, page 360
spec
13 - Seal
t to the co
❑ Replace
rrectne
14 - Turbocharger
s
❑ Unit with exhaust manifold and pressure cell (cannot be replaced separately)
s
ProCarManuals.com
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f
inform
⇒ “3.2 Turbocharger with Exhaust Manifold, Removing and Installing, Engine Codes CBEA, CJAA”, page
mer
276 .
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15 - Nut
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❑ 23 Nm
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❑ Replace um
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❑ Grease the exhaust manifold stud bolts with Hot Bolt Paste - G 052 112 A3- .
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❑ 20 Nm
18 - Nut
❑ 23 Nm
❑ installed on the hex stud bolt -item 17- ⇒ Item 17 (page 272) on the turbocharger
19 - Nut
❑ 23 Nm
❑ Secure on the exhaust manifold with the heat shield -item 16- ⇒ Item 16 (page 272)
20 - Control Line
❑ 23 Nm
❑ Do not change the angles of the control line
❑ between the EGR housing -item 16- ⇒ Item 16 (page 399) and Exhaust Pressure Sensor 1 - G450-
-item 1- ⇒ Item 1 (page 361)
❑ To loosen at the housing -item 16- ⇒ Item 16 (page 399) remove the exhaust gas recirculation filter
21 - Filter
❑ For the EGR
22 - Support
❑ For the turbocharger

23 - Seal
❑ Replace
24 - Banjo Bolt
❑ 60 Nm
❑ Replace
25 - O-Ring
❑ Replace
26 - Oil Return Pipe
27 - Bolt
❑ 15 Nm
28 - Pulsation Damper
❑ To the »hot« side connecting hose, upper -item 13- ⇒ Item 13 (page 291)
29 - Connecting Pipe
Caution
Make sure the connect‐
ing pipe decoupling ele‐
ment does not bend or
ProCarManuals.com
stretch. Cracks could de‐

velop.
❑ between the exhaust manifold and intake manifold -item 5- ⇒ Item 5 (page 332)
❑ Replace
30 - Nut
AG. Volkswagen AG d
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❑ 20 Nm Volksw
oes
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❑ Grease the exhaust manifold
ris
e stud bolts with Hot Bolt Paste - G 052ra112
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31 - Connecting Pipe au ra
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❑ From the exhaust gas recirculation housing -item 2- ⇒ Item 2 (page 398)
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❑ For removing and installing, also loosen the connections -item 33- ⇒ Item 33 (page 273) on the turbo‐
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32 - Seal
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33 - Connection
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34 - O-Ring
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35 - Intake Scoop
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❑ Clean if there is contamination
nform
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❑ from the intake hose on the air filter -item 1- ⇒ Item 1 (page 336)
m
❑ With Positive Crankcase Ventilation Heating Element - N79-

a
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tion in
Removing:
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– Disconnect the crankcase ventilation hose at the intake scoop.

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3. Turbocharger 273
– Remove the bolt -item 36- ⇒ Item 36 (page 274) .
– Rotate the intake scoop clockwise and remove it from the connections -item 33- ⇒ Item 33 (page 273) .
Installing:
– Clean the intake scoop. It must be free of oil and grease.
– Slide the intake scoop onto the connections -item 33- ⇒ Item 33 (page 273) and rotate it counterclockwise
until it engages on the connections.
– Tighten the bolt -item 36- ⇒ Item 36 (page 274) .

– Install a new crankcase ventilation hose.
36 - Bolt agen
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37 - Exhaust Gas Temperature Sensor 1ut-h G235-
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❑ 45 Nm ss c
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❑ Remove using Diesel Engine Tool Set - 17mm - T10395A-
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⇒ Fig. ““Installed Position, Exhaust Gas Temperature Sensor with Angled Shaft”“ , page 274 .
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❑ Only grease the threads with Hot Bolt Paste - G 052 112 A3- .
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es, in part or in w
Installed Position, Exhaust Gas Temperature Sensor with Angled
t to the co
Shaft
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Note
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Always keep the dimension -a- of 3 to 5 mm to the threaded con‐

nection for the turbocharger support when installing the Exhaust
nf
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Gas Temperature Sensor with an angled shaft.
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Overview - Front Exhaust Pipe with Particulate Filter. Refer to

⇒ “2.1 Overview - Front Exhaust Pipe with Particulate Filter”, page
388 .

1 - 10 Nm
2 - Oil Supply Line
ling. Refer to
Turbocharger,VRemov‐ wage es n
olks ot g
ing and Installing”,
ed by page ua
ran
182 . horis tee
ut or
❑ Before ss installing, check
a ac
the oil supply line for
ce
le
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clear passage
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❑ Before installing, fill tur‐
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bocharger with engine
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3 - Turbocharger
es, in part or in w
t to the co
❑ Replace completely to‐
gether with the exhaust
manifold and the pres‐
rrectness of i
sure cell
l purpos
ling. Refer to
⇒ “3.3 Turbocharger
nform
ercia
with Exhaust Manifold,

ProCarManuals.com

m
a
ling, Engine Codes
com
CBDA, CBDB, CEGA”, tion in

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4 - Vacuum diaphragm
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Pressure Actuator Posi‐ Cop py
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ling. Refer to
agen
Prote AG.
⇒ “3.4 Vacuum Dia‐
phragm with Charge Air
Pressure Actuator Position Sensor G581 , Replacing”, page 282 .
5 - Connector
❑ to the Charge Air Pressure Actuator Position Sensor - G581-
6 - Heat shield
7 - Seal
❑ Replace
8 - Connecting Pipe
❑ To EGR cooler
9 - 20 Nm
10 - Decoupling element
❑ do not bend or stretch
11 - Exhaust Gas Temperature Sensor 1 - G235-
❑ 45 Nm
❑ Coat the thread on the sensor with Hot Bolt Paste - G 052 112 A3-
⇒ Fig. ““Installed position, exhaust gas temperature sensor with angled shaft”“ , page 276 .
3. Turbocharger 275
12 - 10 Nm
13 - Bracket
❑ For oil supply line
14 - Heat Shield
15 - Support
❑ Between turbocharger and cylinder block
16 - Seal
❑ Replace
17 - Banjo Bolt, 60 Nm
❑ Replace
18 - Oil Return Pipe
19 - 15 Nm
20 - Pulsation Damper
21 - 10 Nm
Installed position, exhaust gas temperature sensor with angled

shaft
ProCarManuals.com
Note
Always keep the dimension -a- of 3 to 5 mm to the threaded con‐

nection for the turbocharger support when installing the Exhaust
Gas Temperature Sensor with an angled shaft.
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Rep. Gr.21 - Turbocharger, Supercharger
Removing
Caution
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page 290 , Overview - Charge Air Cooling System Com‐
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♦ Replace the connecting pipe between the exhaust mani‐
fold and intake manifold -item 29- ⇒ Item 29 (page 273) .
rrectness of i
♦ Clean the entire charge air circuit and replace the charge
l purpos
air cooler if necessary.

♦ Check the housing and the exhaust gas recirculation cool‐
nf
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⇒ “3.1 Overview - Exhaust Gas Recirculation System
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Components”, page 398 , Overview - Exhaust Gas Re‐
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♦ Check the oil lines on the turbocharger for contamination
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– Remove the particulate filter with NOx reduction catalytic con‐
verter. Refer to
verter, Removing and Installing”, page 369 .
Caution

– Remove the Exhaust Gas Temperature Sensor 1 - G235- with

Diesel Engine Tool Set - 17mm - T10395A- .
– Remove the control line between the EGR housing and the
Exhaust Pressure Sensor 1 - G450- -item 8-
⇒ Item 8 (page 398) .
– Remove the housing with the exhaust gas recirculation cooler.
Refer to
ponents”, page 398 , Overview - Exhaust Gas Recirculation
Components
3. Turbocharger 277

Sensor - G581- -2- on the on the turbocharger vacuum dia‐
phragm.
– Disconnect the vacuum hose -3- at the turbocharger vacuum
diaphragm.
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– Disconnect the »black« connector for the Exhaust Gas Tem‐

perature Sensor 1 - G235- -2- at the plenum chamber bulk‐
head.
– Guide the wire out of the retainer on the plenum chamber
– Remove the connecting pipe -item 31- ⇒ Item 31 (page 273) .
– Remove the oil supply line. Refer to
⇒ “4.3 Oil Supply Line to Turbocharger, Removing and Instal‐
ling”, page 182 .
– Remove the hex bolt -item 17- ⇒ Item 17 (page 272) from the
turbocharger support.
– Remove the heat shield -item 16- ⇒ Item 16 (page 272) on the
exhaust manifold.
– Remove the exhaust manifold nuts -item 15-
⇒ Item 15 (page 272) .
– Remove the turbocharger with the exhaust manifold from the
cylinder head. Turn it so that the intake side points downward
ProCarManuals.com
and remove the turbocharger with the exhaust manifold down‐

ward.
Installing
Caution
Before installing, check if the oil swreturn

agen pipe decoupling
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hole
spec
• Position the charge air pipe connecting hose before securing

es, in part or in w
t to the co
the turbocharger.
• Pay attention to the installation position of the Exhaust Gas
Temperature Sensor 1 - G235- . Refer to
rrectness of i
⇒ Fig. ““Installed Position, Exhaust Gas Temperature Sensor

with Angled Shaft”“ , page 274 :
l purpos
• Replace the banjo bolt with the turbocharger support gaskets

as well as the oil return pipe O-rings.
nform
ercia
• Do not stretch the oil return pipe decoupling element when

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Removing and Installing, Engine Codes

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3. Turbocharger 279
Caution

tions. Refer to
page 269 .
work.
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prevent subsequent damage. n AG. Volkswagen AG ge does
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If foreign objects are found in the charge air system:
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⇒ “4.2 Overview - Charge Air Cooler Components”, ility
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♦ Clean the entire charge air circuit and replace the charge
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t to the co
♦ Check the housing and the exhaust gas recirculation cool‐

rrectness of i
⇒ “4.1 Overview - Exhaust Gas Recirculation System

Components”, page 403 , Overview - Exhaust Gas Re‐
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circulation Components
♦ Check the oil lines on the turbocharger for contamination
nform
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and foreign objects. Refer to

m
⇒ “3.1 Overview - Turbocharger with Exhaust Manifold

at
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and Attachments”, page 270 , Overview - Turbocharger

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– Remove the intake line -1- and disconnect from the Charge
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Air Pressure Actuator Position Sensor - G581- -2- on the tur‐
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– Disconnect the vacuum line -3- on the turbocharger.
c by lksw
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– Disconnect the connector for Exhaust Gas Temperature Sen‐

sor 1 - G235- -1- on the plenum chamber bulkhead and guide
the wire out of the retainers.
G. Volkswagen AG d
– Remove the oil supply line on the turbocharger
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es, in part or in w
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– Remove the charge air pipe screw -1-, loosen the clamp -2-
and pull off the connecting hose from the turbocharger as far
rrectness of i
as possible.
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– Remove the particulate filter. Refer to

⇒ “2 Exhaust System, Engine Codes CBDA, CBDB and CE‐
nf
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GA”, page 388 .
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Caution
AG.

– Remove the Exhaust Gas Temperature Sensor 1 - G235- .

– Remove the right axle shaft from the bevel box. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 .
3. Turbocharger 281
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– Remove the upper screw -arrow- from the support on the tur‐
un
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bocharger.
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– Remove the heat shield on the exhaust manifold.
ole,
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– Remove the exhaust manifold nuts.
t to the co
– Remove the turbocharger and then turn it so that the intake
side is facing downward and the remove the turbocharger
downward.
rrectne
Installing
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Before installing, check if the oil return line decoupling element
om
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♦ Position the charge air pipe connecting hose before securing
ProCarManuals.com
Prote AG.
the turbocharger.
♦ Pay attention to the installation position of the Exhaust Gas
Temperature Sensor 1 - G235- . Refer to
⇒ Fig. ““Installed position, exhaust gas temperature sensor
with angled shaft”“ , page 276 :
♦ Replace the banjo bolt for the turbocharger support and the
O-rings for the oil return line.
♦ Be careful not to overstretch the decoupling element for the oil
return line when installing the turbocharger support.
3.4 Vacuum Diaphragm with Charge Air

Pressure Actuator Position Sensor -
G581- , Replacing
♦ Actuator Socket - 10mm - T10422A-
♦ Ring Wrench 10x12mm - T10423-
Caution
The specified special tools, in particular the Actuator Socket -

10mm - T10422A- , are designed exclusively for use according
to the following work procedure and may not be used for other
screw connections. Higher torques can cause deformation.

Note
There is a replacement part kit available for replacing the vacuum

diaphragm with Charge Air Pressure Actuator Position Sensor -
G581- . Refer to Parts Catalog.
AG. Volkswagen AG d
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– Remove the air filter housing with theorimass
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- All Vehicles Except Jetta from MY 2011
form
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– Press the release buttons and remove the crankcase ventila‐
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tion connecting pipe -1- from the cylinder head cover.
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– Free up the vacuum hoses -arrows-.

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– Unscrew the bolt -2- (permanent) and tilt the air duct pipe with
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the intake tube toward the rear and remove from the turbo‐
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charger. Cop py
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– Seal the opening on the turbocharger with the cap from the p by
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Jetta from MY 2011

– Free up the vacuum hoses -arrows-.
3. Turbocharger 283
– Press the release buttons and remove the crankcase ventila‐

tion connecting pipe -3- from the cylinder head cover.
– Disconnect -2-.
– Loosen the bolt -2- (permanent) and tilt the air guide pipe with
the intake tube backward and remove from the turbocharger.
– Seal the opening on the turbocharger with the cap from the
– Remove the bolt -1- and the warm air pipe from the guide
-2-.
ProCarManuals.com

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– Remove the vacuum line on theolkturbocharger.
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– Unscrew the securing nut oris-arrow- of the oil supply line/vacuum
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Caution
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When disconnecting the oil supply line, the connection must

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– Prepare 14 mm open end wrench as shown for counter-hold‐

t to the co
ing purposes.
14 mm Tool for Counter-Holding the Oil Supply Line Connection

rrectne
Fitting
♦ A = 110 mm
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♦ B = 25 mm
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– Counter hold the connection using the Wrench - Open End -

14mm - T10461- and remove the oil supply line -arrow- from
the turbocharger using the Union Nut Socket - T40055- .
– Seal the oil supply opening on the turbocharger with plugs
from the replacement part kit.
Jetta from MY 2011

– Set the Actuator Socket - 10mm - T10422A- toethe
n AGdimension
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– Position the Ring Wrench 10x12mm - T10423- -1- and Actua‐
tor Socket - 10mm - T10422A- -2- with the Reversible Ratchet
rrectness of i
-3- as shown.
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– Counterhold the lock nut -B- with the Ring Wrench 10x12mm
- T10423- and unscrew the securing nut -A- with the Actuator
Socket - 10mm - T10422AA- from the control rod.
3. Turbocharger 285
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤wa, gJetta
en AG.2011
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– Unscrew the bolts of the pressure cell -arrows- and au remove
th or
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vacuum diaphragm -A-. ss
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Only use new screws and nuts from the replacement part kit.
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– Remove the lower nut of the control rod from the new vacuum
diaphragm if necessary.
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– Screw the lock nut onto the control rod by hand to the stop in
the direction of the pressure cell.
ss
– Conduct the control rod through the adjusting lever on the tur‐
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cial p
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bocharger, install the vacuum diaphragm -A-, and insert the
nform
bolts.
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– Tighten the bolts -arrows- to 8 Nm.
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Ensure that the guide moves easily on the control rod. C py
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– Remove the protective cap, install the oil supply line on the
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turbocharger, and tighten to 22 Nm.
AG.
– Connect the connector -2- to the Charge Air Pressure Actuator

Position Sensor - G581- and connect the heat shield mat.
– Connect the Vehicle Diagnostic Tester .
Selecting Operating Mode:
– Press the “vehicle self-diagnosis” button on the display.
Vehicle System Selection:
– Press the “01 - engine electronics” button on the display.
The display shows the control module identification and the cod‐
ing for the engine control module.
Selecting Diagnosis Function:
– Press the “011 - measured values” button on the display.
– Enter the measured value block “120” via the 10-key keyboard
and confirm the input with the “Q” button.
– Connect the Hand Vacuum Pump - VAS6213- to the vacuum
diaphragm.
– Set a voltage of 0.760 V by generating a vacuum while ob‐
serving the lowest value of the measured value block.
Caution
Maintain a constant vacuum and voltage of 0.706 V during the

subsequent adjustment procedure for the control rod.

– Slowly screw lock nut -B- of the control rod down by hand. The
adjusting lever is on the lower »stop«.
– Counter-hold lockwnut gen-B-
AG.and turn securing
Volkswagen AG
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no pressure, a value of 3.30 to 3.90 V must be set.
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– Attach the Actuator Socket - 10mm - T10422AA- , counterhold
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the lock nut -B- with the Ring Wrench 10x12mm - T10423- and
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Caution
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Generate a vacuum of 0.75 ± 0.05 bar (10.87 ± 0.72 psi) at the
vacuum diaphragm to ensure that the adjustment lever is at the
rrectness of i
»stop«. A voltage of 0.760 V must be set in this process.
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Voltage Value OK.
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– Manually press the locking plate onto the control rod and turn
atio
m
it 90° in the direction of -arrow-.

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– Seal the control rod/nut connection with sealing wax from the
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– Counterhold the lock nut -B-, loosen the control rod nut -A- and
correct the value by rotating the lock nut -B-.
– Counter-hold the lock nut -B-, counter-rotate the nut -A-, and
tighten with the Actuator Socket - 10mm - T10422AA- .
– Manually press the locking plate onto the control rod and turn
it 90° in the direction of -arrow-.
– Seal the control rod/nut connection with sealing wax from the
Continuation
3. Turbocharger 287
– Place the securing nut -arrow- of the oil supply line/vacuum

line connection on the cylinder head and tighten.
– Remove the cap on the turbocharger.
– Reassemble the engine.
– Start the engine and delete the DTC memory.
– Check the adjustment as follows:
Selecting Diagnosis Function:
– Press the “006 - basic setting” button on the display.
– Enter the measured value block “120” via the 10-key keyboard
and confirm the input with the “Q” button.
– Press the “activate” button on the lower half of the screen.
. Volkswagen AG
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– Observe the value in the lower window. It must fluctuate Vol
kbe‐
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tween 0.65-0.85 V and 3.30-3.90 V (pressure cell alternates
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4 Charge Air System

⇒ “4.2 Overview - Charge Air Cooler Components”, page 290
⇒ “4.3 Connector Coupling Between Charge Air Cooler and Con‐
necting Hose, Disassembling and Assembling”, page 291
⇒ “4.4 Charge Air System, Checking for Leaks”, page 293
⇒ “4.5 Vacuum Hose Connection Diagram”, page 295
⇒ “4.6 Vacuum Hose Connection Diagram, Engine Codes CBDA,
CBDB, CEGA”, page 296
⇒ “4.7 Vacuum System, Checking”, page 297

AG. Volkswagen AG d
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♦ Charge air system must be properly sealed.
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♦ All hose connections for the charge air system are secured by
pt
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screw-type clamps, spring-type clamps or by connector cou‐
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plings. Be sure to follow the assembly guidelines when instal‐
ab
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Connecting Hose, Disassembling and Assembling”,
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page 291 .
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♦ Tighten the screw-type clamps by hand - using a screwdriver t to the co

is not permitted.
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4. Charge Air System 289

4.2 Overview - Charge Air Cooler Compo‐

nents
Caution

tions. Refer to
page 269 .
work.
1 - Bolt
❑ 5 Nm
2 - Bearing
❑ For the charge air cooler
ProCarManuals.com
3 - Charge Air Cooler

❑ To remove, bring the
lock carrier into the serv‐
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⇒ “4.3 Connector Cou‐

pling Between Charge
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bling and Assembling”,
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❑ »Cold« side, top

8 - Charge Air Pressure Sensor - G31-

❑ With Intake Air Temperature Sensor - G42-
9 - Bolt
❑ 3 Nm
10 - Rubber Grommet
11 - Bolt
❑ 8 Nm
12 - Charge Air Pipe
❑ »Cold« side
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❑ Replace the seal if it is damaged or if there are leaks.
❑ Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and Assembling.
rrectne
Refer to
⇒ “4.3 Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and As‐
s
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4.3 Connector Coupling Between Charge

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Air Cooler and Connecting Hose, Disas‐

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– Disconnect the connector coupling without using tools.
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– Release the connector coupling by pulling the clip -1-. Remove
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The connector coupling sealing ring can be damaged if the
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clamp is in locked position when installing. This would result in
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a leak. Follow the assembly instructions.
– Clean the sealing surfaces in the connector coupling.

– When replacing the seal, lay the seal in the groove of the con‐
necting hose. Ensure gasket is completely seated in groove
all the way around.
– Lightly oil the sealing surfaces and the seal.
– Bring the clamp -1- into the release position.

– Slide the connecting hose all the way into the clutch. Pay at‐
tention to the positioning tab -2- while doing this.
– Bring the clamp into the locked position -4-. During this, the
clamp engages in the groove -3-.
– Then press in the connecting hose again.
– Check that the connector coupling is correctly positioned and
locked by pulling on the connecting hose.
Version without Positioning Tab
– When replacing sealing ring, lay ring in charge air hose
groove. Ensure gasket is completely seated in groove all the
way around.
– Oil the sealing surfaces and the gasket.
– Bring the clip into the release position -1-.
– Slide the charge air hose into clutch until it stops.

– Bring the clip into the lock position -2- and then press the
charge air hose back again.
– Check for correct seating and proper locking of connector bygen AG. Volkswagen AG d
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tions. Refer to
page 269 .
work.

Test Sequence
– Remove the intake hose -1- from the Mass Airflow Sensor -
G70- . Loosen the spring clamps using the Hose Clip Pliers -
VAS6362- .
– Insert the Turbo System Tester Kit - Adapter 1 - VAG1687/1-
in the intake hose -1- and secure it with a clamp.
Prepare the Turbo System Tester Kit - VAG1687- as follows:
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– Fully turn out the pressure regulator valve -2- to the closed
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Note
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sure regulator valve -2- can be turned.
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– Connect the Turbo System Tester Kit - VAG1687- to the Turbo

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System Tester Kit - Adapter 10 - VAG1687/10- as shown.

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– Connect the pressure hose -1- (pressurized air supply) to the

Turbo System Tester Kit - VAG1687- .
Note
If water is located in viewing glass, drain it via the water drain plug
-6-.
– Open the valve -3-.

– Set pressure to 0.5 bar (7.2 psi) using the pressure regulator
valve -2-.
Caution
The pressure must not exceed 0.5 bar (7.2 psi)! A pressure set
too high may damage the aengine.
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♦ Connector Coupling Between Charge Air Cooler and Con‐

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necting Hose, Disassembling and Assembling. Refer to

⇒ “4.3 Connector Coupling Between Charge Air Cooler and
Connecting Hose, Disassembling and Assembling”,
rrectness of i
page 291
l purpos
♦ Small leaks on the intake side of the turbocharger are permit‐

ted because the intake hoses are not designed for positive
pressure.
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♦ A small quantity of air dissipates via the valves in the engine.

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For this reason a pressure retention test is not possible.

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charge air system when repairing. Refer to
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circuit by pulling off the coupling from the Turbo System Tester
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Kit - Adapter 10 - VAG1687/10- .
4.5 Vacuum Hose Connection Diagram
Caution
When routing the vacuum lines, make sure they are not kinked,
twisted or pinched. They could disable the vehicle.

❑ On the turbocharger
❑ With the Charge Air
Pressure Actuator Posi‐
tion Sensor - G581-
ling. Refer to
tion Sensor G581 , Re‐
placing”, page 282 .
2 - Wastegate Bypass Regula‐
tor Valve - N75-
3 - From Brake Booster
4 - To the Vacuum Pump
5 - Connecting Piece
❑ At the vacuum pump
6 - Check Valve
❑ Pay attention to the in‐
stalled position: the
white connection faces
ProCarManuals.com
the junction piece

-item 10-
❑ Checking. Refer to
⇒ “4.7 Vacuum System,
Checking”, page 297 ,
Vacuum System,
Checking
7 - Air Filter
8 - Muffler
9 - Cylinder Head Cover agen
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When routing the vacuum lines, make sure they are not kinked,
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2 - Wastegate Bypass Regula‐
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3 - Muffler
4 - Air Filter
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5 - To the Brake Booster

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Valve - N345-
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9 - Cylinder Head Cover
❑ For the EGR cooler
change over
4.7 Vacuum System, Checking

⇒ “4.7.1 Supply Line and Check Valve, Checking”, page 297
⇒ “4.7.2 Control Line to Turbocharger, Checking”, page 299 .
4.7.1 Supply Line and Check Valve, Checking

♦ Hand Vacuum Pump - VAS6213-

Caution
♦ When routing the vacuum lines, make sure they are not
kinked, twisted or pinched. They could disable the vehicle.
tions. Refer to
page 269 .
work.

Remove the vacuum hose on the lower connection from the
Wastegate Bypass Regulator Valve - N75- -arrow in II-.
– Seal the open hose end with a suitable blind plug.
ProCarManuals.com
Note
Do not use threaded bolts or pins.

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line connection.
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If the vacuum does not decrease:

– First disconnect the hose at the Hand Vacuum Pump -
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VAS6213- .
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– Remove the blind plug from the hose end.

– If the check valve -item 6- ⇒ Item 6 (page 296) functions, a
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noticeable hissing can be heard as the vacuum pressure re‐

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– Connect all the vacuum hoses.
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– Check the control line to the turbocharger. Refer to
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⇒ “4.7.2 Control Line to Turbocharger, Checking”,
agen
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page 299 .

4.7.2 Control Line to Turbocharger, Checking

♦ Hand Vacuum Pump - VAS6213-
Caution
♦ When routing the vacuum lines, make sure they are not
kinked, twisted or pinched. They could disable the vehicle.
tions. Refer to
page 269 .
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– Remove the vacuum hose at the center connection
ss of the
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– Watch the pressure gauge on the Hand Vacuum Pump -

VAS6213- for approximately 30 seconds.
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– Install the engine cover. Refer to Cop py
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If the vacuum does not decrease:
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Switch-Over Valve - N345- -arrow-. es, in part or in w
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– Connect the Hand Vacuum Pump - VAS6213- to the removed
hose and generate a vacuum pressure of 0.6 bar (8.7 psi).
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– Watch the pressure gauge on the hand vacuum pump for ap‐
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proximately 30 seconds. The vacuum must not drop.

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– Remove the vacuum hose on the vacuum diaphragm for the

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– Connect the Hand Vacuum Pump - VAS6213- with the sup‐
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EGR cooler. Refer to

ProCarManuals.com

ponents”, page 403 .
♦ If a fault is not identified at the vacuum diaphragm, replace the
vacuum line on the EGR Cooler Switch-Over Valve - N345- .
♦ Install the engine cover. Refer to

5 Special Tools
♦ Turbo System Tester Kit - VAG1687-

ProCarManuals.com
AG. Volkswagen AG d
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♦ Hand Vacuum Pump - VAS6213- s au ra
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♦ Wrench - Open End - 14mm - T10461-

4-Cylinder Diesel Engine (2.0L Engine, Common Rail) - Edition
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23 – Diesel Fuel Injection

Diesel Direct Fuel Injection System
WARNING

space.
vacuum lines.
or hot components.
AG. Volkswagen AG d
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When doing any assembly work, especially in the engine com‐ s
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♦ The fuel or fuel lines in fuel system can become very hot
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♦ Always wear protective eyewear, safety gloves and pro‐
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tective clothing when performing any work on the fuel
es, in part or in w
system to avoid eye injuries and burns.
t to the co
♦ In addition, the fuel system is under pressure! Before
opening the system, place rags around the connection
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area and release pressure by carefully loosening the con‐
nection!
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system must be filled in order to bleed it. Refer to

⇒ “3.9 Fuel System, Filling/Bleeding”, page 328 . (Run‐
m
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ti
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on in
be avoided).
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and operated by a second person from this location.
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If the vehicle is involved in a collision while testing and measuring
equipment is operated from the front passenger seat, the person
sitting in that seat could be seriously injured when the airbag de‐
ploys.
To Reduce the Risk of Personal Injury and/or Damage to the Fuel
Injection and Glow Plug System, Always Observe the Following:
♦ Only disconnect and reconnect wires for glow plug and fuel
injection systems, including test leads, when the ignition is
switched off.
1. Safety Precautions when Working on Diesel Direct Fuel Injection System 303
♦ The Battery - A- may only be disconnected and connected

when the ignition is switched off, otherwise it could damage
the Engine Control Module - J623- .
ProCarManuals.com
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304 Rep. Gr.23 - Diesel Fuel Injection


tions
When Working on the Fuel Supply/Injection System, Pay Careful
Attention to the Following “7 rules” of Cleanliness:
Volkswa
♦ Thoroughly clean the connection
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♦ In addition, do not let diesel fuel flow onto the coolant hoses.
If necessary, the hoses must be cleaned again immediately.
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Replace corroded hoses.
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2. Guidelines for Clean Working Conditions 305

3 Diesel Direct Injection System

⇒ “3.2 System Overview”, page 307
⇒ “3.3 Overview - Fuel System”, page 311
page 315
⇒ “3.5 Fuel Pressure Regulator Valve N276 , Checking”,
page 321
⇒ “3.6 Fuel Pressure Regulator Valve N276 , Removing and In‐
stalling”, page 322
⇒ “3.7 Fuel Pressure Sensor G247 , Removing and Installing”,
page 323
⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”, page
325
⇒ “3.9 Fuel System, Filling/Bleeding”, page 328
⇒ “3.10 Fuel System, Performing Leak Test”, page 329
⇒ “3.11 Pressure Retaining Valve in Fuel Return, Checking”, page
330
ProCarManuals.com

page 331
⇒ “3.13 Intake Manifold, Removing and Installing”, page w333
agen
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⇒ “3.16 Air Filter Element, Removing and Installing”, page 339
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must be checked. Refer to Vehicle Diagnostic Tester in “Guided
Functions”.

3.2 System Overview

⇒ “3.2.1 System Overview”, page 307
3.2.1 System Overview
DANGER!

tions. Refer to
page 305 .
system must be filled in order to bleed it. Refer to . Volkswage
⇒ “3.9 Fuel System, Filling/Bleeding”, pageks328
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3. Diesel Direct Injection System 307

1 - Fuel Metering Valve - N290-

❑ Do not open
2 - High Pressure Fuel Pump
ling. Refer to
⇒ “3.8 High Pressure
Fuel Pump, Removing
and Installing”,
page 325 .
❑ The fuel system “must”
always be filled after re‐
placing (never run dry)
(refer to
⇒ “3.9 Fuel System, Fill‐
ing/Bleeding”,
page 328 ), Fuel Sys‐
tem, Filling.
3 - Fuel Pressure Sensor -
G247-
ling. Refer to
⇒ “3.7 Fuel Pressure
Sensor G247 , Remov‐
323 .
ProCarManuals.com
4 - Rail Element (High Pres‐

sure Reservoir)
5 - Fuel Pressure Regulator
Valve - N276- , 80 Nm
ling. Refer to AG. Volkswagen AG d
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⇒ “3.6 Fuel Pressure Volksw
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⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”, page 315 .
7 - Fuel Return Lines
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❑ The fuel return line must be routed correctly. They may be replaced only with the pressure retaining
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❑ The pressure retaining valve must be replaced completely with the fuel return lines -item 7-
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⇒ “3.11 Pressure Retaining Valve in Fuel Return, Checking”, page 330 . Prote AG.

9 - Fuel Tank
❑ Overview - Fuel Tank, All Vehicles Except Jetta from MY 2011. Refer to
⇒ “4.2 Overview - Fuel Tank, All Vehicles Except Jetta from MY 2011”, page 231
❑ Overview - Fuel Tank, Jetta from MY 2011 Only. Refer to
⇒ “4.3 Overview - Fuel Tank, Jetta from MY 2011 Only”, page 233
10 - Fuel Filter
❑ Overview - Fuel Filter. Refer to ⇒ “6.2 Overview - Fuel Filter”, page 249 .
11 - Auxiliary Fuel Pump - V393-
⇒ “6.6 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing and Installing”, page 259 .
3.2.2 System Overview - Engine Codes

CBDA, CBDB, CEGA
DANGER!

ProCarManuals.com
♦ Pay attention to the guidelines

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⇒ “6.3 Fuel Filter, Re‐
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5 - Fuel Temperature Sensor -

G81-
6 - High Pressure Pump
❑ After replacing, the fuel
tank must be filled (nev‐
er run dry). Refer to
⇒ “3.9 Fuel System, Fill‐
ing/Bleeding”,
page 328 .
ling. Refer to
⇒ “3.8 High Pressure
Fuel Pump, Removing and Installing”, page 325 .
7 - Fuel Metering Valve - N290-
❑ Must not be removed
8 - Fuel Pressure Regulator Valve - N276-
⇒ “3.6 Fuel Pressure Regulator Valve N276 , Removing and Installing”, page 322 .
9 - High Pressure Reservoir (Rail)
10 - Fuel Pressure Sensor - G247-
⇒ “3.7 Fuel Pressure Sensor G247 , Removing and Installing”, page 323 .
11 - Pressure Retaining Valve
❑ The pressure retaining valve always maintains a residual pressure (control quantity) of approximately 10
bar (145.03 psi) in the fuel return lines.
❑ The Piezo injectors need this control quantity for their function.
❑ The pressure retaining valve can be replaced only with the complete fuel return lines.
❑ The engine must run at idle for approximately two minutes after replacing to bleed the fuel system.
❑ Check the pressure retaining valve. Refer to
⇒ “3.11 Pressure Retaining Valve in Fuel Return, Checking”, page 330 .
12 - Fuel Injector (Piezo Injectors)

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♦ If the fuel system components between the fuel tank and

the high pressure fuel pump are removed or replaced,
♦ the basic setting “transfer fuel pump test” must be per‐
formed to vent the fuel system.
♦ If a fuel pump, fuel line (between the fuel tank and the high
pressure fuel pump) or fuel filter is removed or replaced,
♦ the “transfer fuel pump test” basic setting must be per‐
formed »1 time« before starting the engine for the first
time.
♦ If the high pressure fuel pump was removed or replaced,
the “check the transfer fuel pump” basic setting must be
performed »three times« before starting the engine for the
first time.
♦ Fill the fuel tank after installing the high pressure pump.
Refer to

1 - Protective Strip
❑ For the rail element
(high pressure reser‐
voir) -item 7-
and high pressure lines
-item 5-
2 - Fuel Return Lines
❑ With pressure retaining
valve -item 8-
❑ The fuel return line must
be routed correctly.
They may be replaced
only with the pressure
retaining valve.
❑ Run the engine at idle
for approximately two
minutes after replacing
to bleed the fuel system
and then check the fuel
return lines for leaks.
❑ Pressure Retention
Valve in Fuel Return
ProCarManuals.com
Line, Checking. Refer to

⇒ “3.11 Pressure Re‐
taining Valve in Fuel Re‐
turn, Checking”,
page 330 .
3 - Bolt
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6 - Fuel Pressure Regulator Valve - N276- , 80 Nm
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⇒ “3.6 Fuel Pressure Regulator Valve N276 , Removing and Installing”, page 322 .
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7 - Rail Element (High Pressure Reservoir)
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8 - Fuel Temperature Sensor - G81-
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❑ Between the Fuel Temperature Sensor - G81- -item 8- ⇒ Item 8 (page 313) and high pressure fuel pump
rrectness of i
-item 10- ⇒ Item 10 (page 313) .
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10 - High Pressure Fuel Pump
❑ With Fuel Metering Valve - N290- -item 1- ⇒ Item 1 (page 308)
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❑ The fuel system “must” always be filled after replacing (never run dry) (refer to
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11 - Bolt
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❑ white or with white markings
❑ From the Auxiliary Fuel Pump - V393-
❑ Auxiliary Fuel Pump - V393- , Removing and installing. Refer to
⇒ “6.6 Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing and Installing”, page 259
14 - Fuel Pressure Sensor - G247- , 100 Nm
⇒ “3.7 Fuel Pressure Sensor G247 , Removing and Installing”, page 323 .
15 - Bolt
❑ 22 Nm
16 - Tensioning Claw
❑ Replace
❑ Note the installation position Refer to ⇒ Fig. ““Tensioning Bracket Installation Position”“ , page 314 .
17 - Nut
❑ 10 Nm
18 - Fuel Injector Cover
19 - Bolt
❑ 5 Nm
20 - Fuel Injector (Piezo Injector)
❑ The following components and seals and/or O-ring must be replaced at every removal and installation:
“tension bracket”, “copper washer”, “fuel injection unit shaft O-ring” and “fuel injection return O-ring”.
❑ The following components and seals and/or O-ring must be replaced when replacing the fuel injection
unit: “tensioning claw”, “fuel injection line”, “copper washer” “fuel injection unit shaft O-ring” “fuel injection
unit return O-ring”
❑ When installing, the fuel injectors -item 5- ⇒ Item 5 (page 312) and high pressure lines may only be
installed on the same cylinder as before.
⇒ “3.4 Fuel Injector (Piezo Injector), Removing and Installing”, page 315 .

21 - High Pressure Line

❑ 28 Nm
❑ between the high pressure fuel pump -item 10- ⇒ Item 10 (page 313) and rail element (high pressure
reservoir) -item 7- ⇒ Item 7 (page 313)
Caution
The high pressure lines
can be reused only after
the following tests:
Check
♦ the sealing cone
on each high pressure
line for the deformation
and cracks.
The
♦ holes for the lines
must not be deformed,
narrowed or damaged.
Do
♦ not use corroded lines
again.
❑ Do not bend the high pressure line to a different angle.

ProCarManuals.com
Tensioning Bracket Installation Position

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Fuel Return Line Differences

-A-, No ribbing: for connecting the overflow oil line, use a clamp.
Refer to the Parts Catalog.
-B-, With ribbing: for connecting the overflow oil line, do NOT use
a clamp
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♦ Puller - Unit Injector - T10055- with Puller - Unit Injector Adapt‐
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page 305 .
work.
Removing:
– Remove the protective strip, if equipped -item 1-
⇒ Item 1 (page 312) .

– Disconnect the connector -1- from the fuel injectors to be re‐

moved.
– Before removing, dry the return line connection on the fuel in‐
jectors that will be removed (for example using a commercially
available detergent).
– Clean and dry the return line connections.
– Cover the return line connection with a rag.
– Remove the fuel return line connections -1- from the fuel in‐
jectors to be removed. Pull them upward to release.
Note
Pay attention to cleanliness. Dirt and contaminants must not enter

the return lines and the connections on the fuel injectors.
– Remove the high pressure line -item 5- ⇒ Item 5 (page 312)

between the rail element (high pressure reservoir) and the fuel
injectors to be removed.
ProCarManuals.com
– Remove the bolts in the cover -item 18-

⇒ Item 18 (page 313) on the fuel injectors to be removed.
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– Raise the cover slightly and rotate it 90° to free up they Vfuel
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– Position the Puller - Unit Injector - aT10055-
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the fuel injector upward by tapping.
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Installing:
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Important Instructions on Installing the Fuel Injectors:
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• The following components, seals and O-rings must be re‐
h re
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placed during every removal and installation: “tensioning claw”
spec
“copper washer”, “O-ring from the fuel injector shaft” and the
t to the co
“O-ring for the fuel injector return”.
• The following components, seals and/or O-rings must be re‐
placed when replacing an injector: “tensioning bracket”, “in‐
rrectne
jection line”, “copper washer”, “injector shaft O-ring” and “fuel
injector return O-ring”
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• Fuel injection unit must be installed in the same cylinder.
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• Check the fuel injectors and installation locations for contam‐
mer
ination before assembling.
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• The fuel injectors must not have any damage.
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• Lubricate all of the O-rings with assembly oil or engine oil be‐
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fore installing.
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If a Used Fuel Injector Is Installed:
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Remove the rust or oil particles with a rag after approximately
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five minutes.
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– To remove the used copper gasket from the fuel injector,

clamp the gasket carefully in a vise until the clamping jaws on
the vise prevent the copper gasket from turning. Pull the fuel
injector out of the copper gasket by hand with slight rotating
and pulling motions.
– Use a plastic socket to install the copper gasket.
– To avoid damaging the O-ring, slide the new O-ring -2- for the
fuel return connection over the assembly mandrel -1-.
– To remove rust particles on the fuel injector sealing surface,
clean the fuel injector duct in the cylinder head with a cloth
dampened with engine oil or rust remover. Do not damage the
sealing flanges.

– Replace the fuel injector shaft seal using the O-Ring Assembly
Sleeve - T10377- .
– Slide the fuel injector cover on.
– Slide the clamping bracket onto the fuel injector and make sure
it is positioned correctly. Refer to
⇒ Fig. ““Tensioning Bracket Installation Position”“ ,
page 314 .
– Insert the fuel injector in the fuel injector shaft.
Caution
When installing the fuel injector nuts, the nut could fall into the
cylinder head. Work very carefully to avoid unnecessary work
or damage.
– Mount the nuts on the tension bracket by hand and tighten

them. Tightening specification -item 17-
⇒ Item 17 (page 313) . . Volkswage n AG n AG d
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– Turn the cover for the fuel injectors to its installed
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– Install the high pressure lines. Refer
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After replacing one or more injectors, the “injector quantity cali‐
hole
spec
bration” and the “injection pressure calibration” for the new injec‐
es, in part or in w
tors must be must be programmed into the engine control module
t to the co
using. Refer to Vehicle Diagnostic Tester in Guided Functions.
3.4.1 High Pressure Lines, Installing rrectness of i

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Caution
Loosen the rail and move it slightly. This makes it possible to

mount the fuel injection line free of tension. The lines must not
be bent or under stress. Long term this would cause the line to
break.
Note
ProCarManuals.com
The following describes installing new fuel injection lines. If in‐

stalling fuel injection lines, which were already removed, then be
sure to check the points listed in -item 5- ⇒ Item 5 (page 312) .
The procedure is otherwise identical.
Installing the Individual Fuel Injection Lines (Cylinder 1 through

4, between the Rail and Fuel Injector)
Tightening specifications. Refer to gen AG
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⇒ “3.3 Overview - Fuel System”, page 311y V.olk not
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– Remove the new fuel injection line ho from the packaging, re‐
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move the plugs and place the line
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– First tighten the union nuts by hand on the fuel injection line
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– Proceed the same way with the other fuel injection lines, if
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– Tighten the rail, if necessary, again to the tightening specifi‐

cation.
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– Tighten the union nuts on all the newly installed fuel injection
lines to the tightening specification using Torque Wrench 1331
5-50Nm - VAG1331- and Union Nut Socket - T40055- .
Installing the Fuel Line (between the High Pressure Pump and
the Rail) or the Entire Wiring Harness
Tightening specifications. Refer to
– Loosen the bolts on the Rail and make sure it is possible to
move the rail, if this was not done before.
– Then remove the fuel line from its packaging, remove the plugs
and position the line immediately between the high pressure
pump and the rail. wagen AG. Volkswagen AG doe
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– First tighten theed union nuts by hand on the fuel injection
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– Proceedss in the same way with the four fuel injection lines, if
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the entire wiring harness has to be installed.
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– Install all three clamps over the fuel line. Make sure they are
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– Install the clamp screws approximately 3 thread turns.

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– Tighten the rail again.
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– Tighten the top clamp on the intake manifold to 8 Nm. rrectness of i
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– Tighten the other two clamps to 8 Nm.

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– Press the return line connections carefully over the sealing

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ring onto the injector (check the sealing ring first for damage). Cop py
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3.5 Fuel Pressure Regulator Valve - N276- ,agen AG. Volkswagen AG d

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rrectne
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– Remove the noise insulation from the injectors.
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– Disconnect the fuel return line -1-.
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– Seal the open return line connection with a plug -1-.

– Connect the return line -2- with a hose -3-.
– Hold his hose -1- inside a suitable container -2- in order to

measure the return quantity.
– Start engine and let it run at idle.
• Target value in 30 seconds: 90 to 110 ml (3.0 to 3.7 ounces).
If the specified value is not attained, then the fuel pressure regu‐
lator valve is faulty.

3.6 Fuel Pressure Regulator Valve - N276- ,

Removing and Installing
Function
The Fuel Pressure Regulator Valve - N276- is located in the rail
element (high pressure reservoir) and maintains a constant pres‐
sure in the rail element and in the high pressure lines (high
pressure fuel circuit).
If the pressure in the high pressure fuel circuit is too high, the Fuel
Pressure Regulator Valve - N276- opens so a portion of the fuel
leaves the rail element through the return line and goes back into
the fuel tank.
If the pressure in the fuel high pressure circuit is too low, the Fuel
Pressure Regulator Valve - N276- closes and seals off the high
pressure side from the low pressure side.
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♦ Follow the safety precautions when workingauon
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direct fuel injection system. Refer to ss c
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– Before removing, clean the threaded area around the Fuel

om
ion
Pressure Regulator Valve - N276- (for example using com‐

c
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his
ate
bore in the rail element (high pressure reservoir).

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♦ Clean carefully, cleaner must not enter the connector.
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♦ The Fuel Pressure Regulator Valve - N276- cannot be used
again.
– Dry the Fuel Pressure Regulator Valve - N276- .

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– Disconnect the connector from the auFuel Pressure
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Regulator or
ac
Valve - N276- -arrow-. ss
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Note
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Seal the rail element bore immediately with a suitable plug to pre‐
vent contaminants from entering.
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♦ Check the Fuel Pressure Regulator Valve - N276- sealing sur‐
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face and threads for damage.
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must be free of oil and grease.
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– First tighten the union nut on the Fuel Pressure Regulator Prote
cted AG.
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Valve - N276- by hand.
– Align the Fuel Pressure Regulator Valve - N276- so the con‐
necting line is not taut after connecting the electrical connec‐
tor.
– Counterhold at the housing hex bolt and tighten the union nut:
– After installing, let the engine run at a moderate speed for a
few minutes and then stop it.
– Check the fuel system for leaks. Refer to
⇒ “3.10 Fuel System, Performing Leak Test”, page 329 .
– Read the DTC memory for the Engine Control Module - J623-
again. Refer to Vehicle Diagnostic Tester in “Guided Func‐
tions”.
3.7 Fuel Pressure Sensor - G247- , Remov‐

ing and Installing
Function
The Fuel Pressure Sensor - G247- (rail pressure sensor) is loca‐
ted in the rail element (high pressure reservoir). It measures the
current fuel pressure in the high pressure system and delivers a
voltage signal to the Engine Control Module - J623- .
If the Fuel Pressure Sensor - G247- malfunctions, the pressure is
controlled via an Engine Control Module - J623- characteristic
map (maximum engine speed is limited to approximately 3000
RPM in emergency operation mode).

DANGER!

tions. Refer to
page 305 .
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ility
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Pressure Sensor - G247- (for example using commercially
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available coolant). Contamination must not enter the bore in
h re
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the rail element (high pressure reservoir).
spec
t to the co
ProCarManuals.com
Note
Clean carefully, cleaner must not enter the connector.

rrectne
– Dry the Fuel Pressure Sensor - G247- .
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– Disconnect the connector from the Fuel Pressure Sensor -

G247- -C-.
– Remove the Fuel Pressure Sensor - G247- .
– Extract the contamination from the rail element bore (threads
and sealing surface). Do not use mechanical tools.
Note
Seal the rail element bore immediately with a suitable plug to pre‐
vent contaminants from entering.
Installing:
Note
♦ Check the Fuel Pressure Sensor - G247- sealing surface and

threads for damage.
♦ Check the sealing surface on the rail element bore.
♦ The Fuel Pressure Sensor - G247- threads are coated with an
anti-friction coating so they must be free of oil and grease.
ProCarManuals.com
– First tighten the Fuel Pressure Sensor - G247- by hand.

AG. Volkswagen AG d
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– Tighten the Fuel Pressure Sensor - G247- : olksw not
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• Tightening specification -item 14- ⇒ Item 14tho(page
ris 313) . nte
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– After installing, let the engine run at a moderate
ss speed for a c
ce
few minutes and then stop it.
le
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– Check the fuel system for leaks. Refer to
y li
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⇒ “3.10 Fuel System, Performing Leak Test”, page 329 .
ility
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– Read the DTC memory for the Engine Control Module - J623-
is n
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again. Refer to Vehicle Diagnostic Tester in “Guided Func‐
ole,
tions”.
spec
t to the co
rrectne
3.8 High Pressure Fuel Pump, Removing
and Installing
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♦ Puller - Pulley - T40064-

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♦ Torque Wrench 1331 5-50Nm - VAG1331- t. Cop py
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♦ Torque Wrench 1331 Insert - Reversible Ratchet - pyri by
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VAG1331/1-
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DANGER!

direct fuel injection system. Refer to agen
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⇒ “1 Safety Precautions when Working bon yV
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♦ Pay attention to the guidelines for
au clean working condi‐ ra
c
ss
tions. Refer to
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⇒ “2 Guidelines for Clean Working Conditions”, nl
pt
du
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page 305 .
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Removing:
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Requirements
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Note
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ProCarManuals.com
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♦ Only remove the high pressure fuel pump when the engine is
ion
c
cold.
in t
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♦ Make sure no contaminants enter the fuel system when re‐

a
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moving the high pressure fuel pump.

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♦ Seal off the connections in the fuel system using the plugs from
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the Engine Bung Set - VAS6122- .
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Procedure Prote
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– Disconnect from the Fuel Temperature Sensor - G81- -1- and
from the Fuel Metering Valve - N290- on the high pressure fuel
pump -2-.
– Loosen the spring clips -3 and 4- with the Hose Clip Pliers -
VAS6362- and disconnect the fuel lines at the high pressure
fuel pump.

– Loosen the high pressure line or fuel lines -arrows- on the in‐
take manifold.
⇒ Item 1 (page 312) .

-C-.
plugs.
Caution
ProCarManuals.com


410 .
AG. Volkswagen AG d
– Remove the toothed belt sprocket from the high pressure fuel
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– Hold the high pressure fuel pump hub with the Counterhold
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Camshaft Gear - T10051- and remove the nut -1-.
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Prote AG.
3. Diesel Direct Injection System
– Position the Puller - Pulley - T40064- with the Puller - Pulley -

Pressure Pad - T40064/1- as shown and remove the hub from
the high pressure fuel pump. Counterhold with a 24 mm open-
end wrench if necessary.
– Remove the high pressure fuel pump bolts -arrows-.
– Remove the high pressure fuel pump.

Installing:
• Make sure no contaminants enter the fuel system when in‐
stalling the high pressure fuel pump.
• Only remove the plugs right before installing the fuel lines.
ProCarManuals.com
• Do not interchange the supply line and the return line.

– First tighten the union nuts for the high G
pressure
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– Make sure the high pressure
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5-50Nm - VAG1331- ss with Torque Wrench 1331 Insert - Re‐ c
ce
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T40055- .
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• Overview - Toothed Belt Drive. Refer to

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• Refer to ⇒ “3.3 Overview - Fuel System”, page 311 . Overview

es, in part or in w
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- Fuel System
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3.9 Fuel System, Filling/Bleeding

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After installing the high pressure pump, it must be filled with

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fuel before starting the engine for the first time (never let the
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Note
♦ When installing the high pressure pump, make sure that no

dirt enters the fuel system.
♦ Only remove the plugs right before installing the fuel lines.
♦ The fuel tank must be filled.
To Fill the High Pressure Fuel Pump with Fuel, Proceed as Fol‐
lows:
– Connect the Vehicle Diagnostic Tester and perform the “Vent
Fuel system” Guided Function.
Note
The fuel pump are activated for 3 minutes.
– Then start the engine.

– After filling the fuel system, let the engine run at a moderate
speed for a few minutes and then switch it off.
ProCarManuals.com
– Check the fuel system for leaks.

– Scan the DTC memory and delete the DTC memory entry if
necessary.
– Test drive the vehicle for at least 20 km/h and testwafull-throttle
gen AG
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does
acceleration at least once. Then check the high y Volkpressure
s
area not
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If there is still air in the fuel system, the engine may switch to
erm
ab
emergency mode during the road test. Turn off the engine and
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erase the DTC memory. Then continue the road test.

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– Scan the DTC memory again.

spec
es, in part or in w
t to the co
3.10 Fuel System, Performing Leak Test

rrectness of i
DANGER!
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Test Sequence Prote AG.


– Let the engine run a few minutes at idle without pressing the
accelerator pedal and then stop the engine. The fuel system
bleeds itself.
– Check the entire fuel supply system for leaks.
If there are leaks despite correct tightening specifications, replace
the affected component.
– Perform a road test where the accelerator pedal is fully de‐
pressed at least one time. Then check the high pressure area
again for leaks.
Note
♦ Follow all applicable safety precautions during a road test.

Refer to ⇒ page 303 .
♦ If there is still air in the fuel system, the engine may switch to
emergency mode during the road test. Stop the engine and
delete all DTC entries. Refer to Vehicle Diagnostic Tester
“Guided Functions”.

3.11 Pressure Retaining Valve in Fuel Re‐

ProCarManuals.com
turn, Checking
Function
AG. Volkswagen AG d
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The pressure retaining valve in the fuel return has the function
Vol
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always maintaining a residual pressure (control quantity)
ed by of ap‐ ara
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The fuel injectors require this control quantity tossfunction correctly. c
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♦ Fuel Return System Tester - VAS6330- (not illustrated)

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Test Sequence
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page 305 .
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⇒ “1.4 Engine Cover, Removing and Installing”, page 90 . t. Cop py
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– Remove the protective strip, if equipped -item 1- p by
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⇒ Item 1 (page 312) .
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– Before removing, clean the cylinder 1 return line connection
using a commercially available detergent, for example.
– Dry the cylinder 1 return line connection.

– Cover the cylinder 1 return line connection with a cleaning

cloth.
– Remove the fuel return line connection from cylinder 1. Press
the connection at the tabs -2- downward and pull the center
piece -1- upward to release.
Note
Pay attention to cleanliness. Dirt must not enter the return line and
the connection on the fuel injectors.
– Install the Fuel Return System Tester - VAS6330- between the

return line connection on the fuel injector and the return line.
– Start the engine and let it run at idle speed.
– Check the pressure on the pressure gauge.
• Specified value: approximately 10 bar (145.03 psi)
If the specified value is not obtained:
– Replace the pressure retaining valve -item 8-
ProCarManuals.com
⇒ Item 8 (page 308) .
AG. Volkswagen AG d
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3.12 Overview - Intake Manifold with Attach‐
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page 305 .
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1 - Intake Manifold
❑ With Intake Flap Motor -
V157-
❑ With intake air swirl op‐
timization
❑ Must not be disassem‐
bled
ling. Refer to
⇒ “3.13 Intake Manifold,
ling”, page 333
2 - Bolt
❑ 8 Nm
AG. Volkswagen AG d
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3 - Seal Volksw not
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❑ Replace rise
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4 - Seal ss a ra
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❑ Replace
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5 - Connecting Pipe
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❑ Replace
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6 - Bolt
orm
❑ 20 Nm
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❑ Use the Socket - Xzn 10 n in

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8 - Bolt
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❑ 8 Nm
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9 - Throttle Valve Control Module - J338-
Prote AG.
❑ For removal, remove the intake manifold. Refer to

⇒ “3.13 Intake Manifold, Removing and Installing”, page 333 .
10 - Bolt
❑ 8 Nm
❑ Refer to ⇒ Fig. ““”“ , page 335
❑ Removing and installing with the Socket - Xzn 8 - T40159-
11 - Bolt
❑ 8 Nm
❑ Removing and installing with the Socket - Xzn 8 - T40159-
12 - Oil Dipstick
❑ Engine Oil Level, Checking. Refer to ⇒ “1.2 Engine Oil, Checking Level”, page 151 .

13 - EGR Vacuum Regulator Solenoid Valve - N18-

❑ With the EGR Potentiometer - G212-
3.13 Intake Manifold, Removing and Instal‐

ling
♦ Socket - Xzn 10 - T10385-
♦ Socket - Xzn 8 - T40159-
VAG1331/1-
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– Tighten the high pressure line union nuts hand-tight.
– Make sure the high pressure line is without tension.
– Tighten the high pressure line using the Torque Wrench 1331
5-50Nm - VAG1331- with Torque Wrench 1331 Insert - Re‐
T40055- .
• Refer to ⇒ “3.3 Overview - Fuel System”, page 311 . Overview
- Fuel System
• Overview - Intake Manifold with Attachments. Refer to
page 331 .
3.14 Overview - Air Filter

⇒ “3.14.1 Overview - Air Filter”, page 335
3.14.1 Overview - Air Filter

1 - Intake Hose
❑ Clean if there is contam‐
ination
❑ To the intake scoop on
the turbocharger
-item 35-
2 - Mass Airflow Sensor - G70-
ling. Refer to
⇒ “3.17 Mass Airflow
Sensor G70 , Removing
and Installing”,
page 341 .
3 - O-Ring
4 - Vacuum Hose
kink free routing
❑ From the muffler
❑ Connection diagram for
ProCarManuals.com
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⇒ “4.5 Vacuum Hose
page 295 .
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Engine Codes CBDA,
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6 - Air Filter Housing Upper
Section
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7 - Air intake connector
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9 - Connecting Hose
❑ Clean if there is contam‐
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10 - Water drain pipe
11 - Lower section of air filter housing
❑ Clean salt residue, dirt and leaves from the air filter housing lower section

12 - 8 Nm
13 - Filter Element
❑ Always use Original air filter insert Parts Catalog.
❑ Follow the replacement intervals ⇒ Maintenance ; Booklet 20.1 ; Service Work “Maintenance Tables”.
❑ Removing and installing. Refer to ⇒ “3.16 Air Filter Element, Removing and Installing”, page 339 .
14 - 3.5 Nm
15 - Connecting Pipe
❑ From the cylinder head cover
❑ For the crankcase ventilation
3.15 Air Filter Housing, Removing and Instal‐

ling
Removing
– Release the tabs -arrows- and open the cover on the air intake.
– Remove the connecting hose for the warm air intake
-item 12- ⇒ Item 12 (page 336) .
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– Remove the bolts -arrows- from the air filter housing upper
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– Lift up the air filter housing upper section and remove the air
filter element.
Installing:
• If the air filter element is very dirty or soaked, dirt particles or
moisture may have contaminated the Mass Airflow Sensor -
G70- and may be causing false mass airflow values. This
results in reduced performance, since a lower injection quan‐
tity is calculated.
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filter housing.
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placed into the mounting of the lower section of the air filter
housing.
– Place upper section of air filter housing on to lower section or
air filter housing carefully and without using excessive force.
When doing this, make sure that upper section of air filter
housing is not placed tilted on the air filter element (pay atten‐
tion to sealing lip of air filter element).

• Tightening specification for the bolts on the air filter housing

upper section -arrows-: 2 Nm.
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4 Engine Control Module

⇒ “4.1 Engine Control Module J623 without Anti-Theft Protection,
Removing and Installing, All Vehicles Except Jetta from MY
2011”, page 343
⇒ “4.2 Engine Control Module J623 with Anti-Theft Protection,
Removing and Installing, All Vehicles Except Jetta from MY
2011”, page 344
⇒ “4.3 Engine Control Module J623 , Removing and Installing,
Jetta from MY 2011 Only”, page 347
4.1 Engine Control Module - J623- without

Anti-Theft Protection, Removing and In‐
stalling, All Vehicles Except Jetta from
MY 2011
♦ Vehicle Diagnosis System - VAS5051B-
Note
If the Engine Control Module - J623- is to be replaced, connect

ProCarManuals.com
the Vehicle Diagnostic Tester and perform the “Guided Functions,

Replace Engine Control Module”.
Removing:
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hole
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4. Engine Control Module 343

– Release the front connector -1- from the Engine Control Mod‐
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– Pry up locking mechanism -2- slightly.
– Then push the Engine Control Module - J623- in the direction
of -arrow- out of the bracket.
– Now release the rear connector from the Engine Control Mod‐
Installing:
– Connect and lock the rear connector to the Engine Control
Module - J623- .
– Slide the Engine Control Module - J623- onto the retaining
plate.
– Push the locking mechanism -2- against the Engine Control
Module - J623- .
– Now connect and lock the front connector -1- to the Engine
Control Module - J623- .
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♦ Hot Air Blower from Wiring Harness Repair Set - VAS1978B- .
♦ Locking pliers
♦ Safety Gloves

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Conditions
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bolt.
– Turn on the Hot Air Blower - VAS1978B- and warm up the bolts
for approximately 20 to 25 seconds.
– Remove the shear bolt by the bolt head with pliers.
The procedure for the second shear bolt is exactly the same.
Do not let the bolts unscrew:

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surfaces -arrows- and then remove the bolts. . Volkswage
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Installing:
– Connect and lock the rear connector to the Engine Control
Module - J623- .
– Slide the Engine Control Module - J623- onto the retaining
plate.

– Now connect and lock the front connector -1- to the Engine
Control Module - J623- .
– Slide the protective housing on to the retaining plate.
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cted AG.
agen
to ⇒ page 303 .
4.3 Engine Control Module - J623- , Remov‐

ing and Installing, Jetta from MY 2011
Only
Note

Removing:

– Remove the E-box cover inside the engine compartment

-arrows-.
Engine Control Module - J623- with Anti-Theft Protection

– Separate the threaded connection -2-.
– Remove the locking mechanism -5-.
– Disconnect the connectors -1 and 3- from the engine control
module.
– Remove bolts -6- and remove the bracket -4-.
ProCarManuals.com
Engine Control Module - J623- without Anti-Theft Protection

– Disconnect the connectors -1 and 3- from the engine control
module.
Continuation for All Vehicles . Volkswagen AG
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– Push the tabs on the side guides y-3- ksw
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Engine Control Module - J623- with Anti-Theft Protection

– Secure the bracket -5- with bolts -6- to the Engine Control
Module.
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– Connect theyconnectors
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– Slide on the E-box cover until it is securely locked -arrows-.
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5 Engine Control Module, Engine Co‐

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If the Engine Control Module - J623- is to be replaced, connect Prote AG.
Removing
– Remove the windshield wiper arms. Refer to ⇒ Electrical
Equipment; Rep. Gr. 92 ; Windshield Wiper System; Wind‐
shield Wiper Arms, Removing and Installing .
terior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Cham‐
ber Cover, Removing and Installing .
– Push the retaining frame in -direction of arrow- downward and
remove the engine control module.

– Push the retainers in the -direction of the arrow- and discon‐

nect the connector.
Installing
– Connect the connector on the engine control module and push

the retainers all the way in -the direction of the arrow-.
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– Mount the engine control module into the retaining frame and
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– Install the windshield wiper arms. Refer to ⇒ Electrical Equip‐

spec
ment; Rep. Gr. 92 ; Windshield Wiper System; Windshield

es, in part or in w
t to the co
Wiper Arms, Removing and Installing .

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5.2 Engine Control Module - J623- with Anti-

Theft Protection, Removing and Instal‐
ling
5. Engine Control Module, Engine Codes CBDA, CBDB, CEGA 351

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ProCarManuals.com
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Removing
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– Remove the windshield wiper arms. Refer to ⇒ Electrical

or
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Equipment; Rep. Gr. 92 ; Windshield Wiper System; Wind‐

t
sd
iva
shield Wiper Arms, Removing and Installing .
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– Push the retaining frame in -direction of arrow- downward and
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remove the engine control module.
AG.
– Remove the shear bolts -arrows- with pliers.

– Slide a screwdriver between both locking plates -arrow-.

– Carefully push the driver in -direction of arrow- and at the same
time bend the locking bracket -1- upward.
– Bend the securing bracket -1- in the -direction of the arrow-

until it can be removed from the connectors.
ProCarManuals.com
– Push the retainers in the -direction of the arrow- and discon‐

nect the connector. wagen AG. Volkswagen AG doe
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5. Engine Control Module, Engine Codes CBDA, CBDB, CEGA 353

– Place the locking bracket -1- on the connectors and press it in

-the direction of the arrow-.
– Install the bolt -2- all the way into the hole in the engine control
module.
– Secure the locking bracket to the Engine Control Module

-arrows- with new shear bolts.
– Tighten the shear bolts evenly until the bolt heads break off
-arrows-.
AG. Volkswagen AG d
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– Mount the engine control module into the retaining frame and ility
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push it in the -direction of arrow- upward. wit

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rior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

t to the co

– Install the windshield wiper arms. Refer to ⇒ Electrical Equip‐
rrectne
ment; Rep. Gr. 92 ; Windshield Wiper System; Windshield

Wiper Arms, Removing and Installing .
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to ⇒ page 303 .

6 Special Tools

equipment required
♦ Puller - Unit Injector -
T10055-
♦ O-Ring Assembly Sleeve -
T10377- AG. Volkswagen AG d
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Gear - T10051-
♦ Union Nut Socket -
T40055-
♦ Puller - Pulley - Pressure
Pad - T40064/1-
5-50Nm - VAG1331-
♦ Torque Wrench 1331 Insert
- Reversible Ratchet -
VAG1331/1-
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♦ Socket - Xzn 10 - T10385-

♦ Socket - Xzn 8 - T40159-
5-50Nm - VAG1331-
VAS6362-
ProCarManuals.com
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♦ Torque Wrench 1332 40-200Nm - VAG1332- s
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6. Special Tools
♦ Window Cutter - VAG1561A-
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♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

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♦ Fuel Return System Tester - VAS6330-
♦ Puller - Unit Injector - Adapter 1 - T10055/1-


♦ Puller - Pulley - Pressure Pad - T40064/1-
ProCarManuals.com
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26 – Exhaust System, Emission Controls

1 Exhaust System
Converter”, page 360
⇒ “1.3 Clamps and Exhaust Gas Temperature Sensor Installed
Position”, page 368
⇒ “1.4 Particulate Filter with NOx Absorption Catalytic Converter,
Removing and Installing”, page 369
⇒ “1.5 Overview - Exhaust Flap Control gModule
AG. VoJ883
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⇒ “1.9 Exhaust System, Installing without Tension”, page 385
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⇒ “1.10 Exhaust System, Checking for Leaks”, page 387
h re
ProCarManuals.com
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Note
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♦ Overview - Exhaust Flap Control Module - J883- with Slip Cat‐

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on
c
⇒ “1.5 Overview - Exhaust Flap Control Module J883 with Slip

in t
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Catalyst”, page 376

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♦ Hose connections are secured with either spring or hose Prote AG.
clamps.
1.2 Overview - Particulate Filter with NOx

Reduction Catalytic Converter
360 Rep. Gr.26 - Exhaust System, Emission Controls

⇒ “1.2.1 Overview - Particulate Filter with NOx Reduction Cata‐

lytic Converter, Engine Code CBEA”, page 361 .
⇒ “1.2.2 Overview - Particulate Filter with NOx Reduction Cata‐
lytic Converter, Engine Code CJAA”, page 365 .
1.2.1 Overview - Particulate Filter with NOx Reduction Catalytic Converter, En‐
gine Code CBEA
1 - Exhaust Pressure Sensor 1

- G450-
❑ Bolted near the oil filler
neck
2 - Heat Shield
3 - Bolt
❑ 8 Nm
4 - Bolt
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7 - Shield
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8 - Heated Oxygen Sensor -
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❑ 52 Nm
❑ Use the Ring Wrench 7-
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Piece Set - 3337- to

loosen and tighten.
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10 - Clamp
❑ 7 Nm
❑ Replace
⇒ “1.3 Clamps and Exhaust Gas Temperature Sensor Installed Position”, page 368 .
❑ -item 14- ⇒ Item 14 (page 272)
❑ 45 Nm
1. Exhaust System 361

❑ Mark the installation position before removal
❑ Wire routing. Refer to ⇒ “1.6 Exhaust System Component Line Routing”, page 378 .
Volkswa AG. gen AG
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13 - Seal Vol
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❑ Installing. Refer to s aut or
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⇒ Fig. ““Install the Gasket Between Exhaust Door sControl Unit -J883- and the NOx Reservoir or Slip
ce
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Catalyst”“ , page 378 .
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⇒ Fig. ““Installation Position of the Clamps Between Exhaust Door Control Unit -J883- and NOx Reservoir
es, in part or in w
t to the co
or Slip Catalyst.”“ , page 378 .
15 - To Exhaust Door Control Unit - J883-
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16 - Oxygen Sensor after Three Way Catalytic Converter - G130-

❑ 52 Nm
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❑ Use the Ring Wrench 7-Piece Set - 3337- to loosen and tighten.
m
❑ Grease only the threads with Hot Bolt Paste - G 052 112 A3- ; Hot Bolt Paste - G 052 112 A3- must not
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17 - NOx Reduction Catalytic Converter
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There is a risk of damag‐
cted agen
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ing the decoupling ele‐
ment between the partic‐
ulate filter and NOx
reduction catalytic con‐
verter. When removing
and installing:
Do
♦ not bend the decou‐
pling element more than
10°.
Do
♦ not stretch the decou‐
pling element.
Do
♦ not damage the wire
mesh on the decoupling
element.
Use
♦ the Transportation
Lock - T10404- to secure
the decoupling element
from stretching.

⇒ “1.4 Particulate Filter with NOx Absorption Catalytic Converter, Removing and Installing”, page 369 .
18 - Bolt
❑ 25 Nm
19 - Mount
20 - From the EGR filter
❑ -Item 9- ⇒ Item 9 (page 399)

21 - Clamp
❑ 3.5 Nm
❑ Replace
❑ 45 Nm
❑ 45 Nm
24 - Nut
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26 - Bracket
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❑ Unit with NOx reduction catalytic converter -item 17- ⇒ Item 17 (page 362) (cannot be disconnected)
Caution
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❑ After replacing, the ash load comparison adaptation must be set to “0”. Refer to Vehicle Diagnostic Tester
28 - Control Wire
❑ 45 Nm

29 - Bolt
❑ 9 Nm
30 - Bracket
❑ For the control line
31 - Bracket
❑ Fastened to cylinder head
32 - Bolt
❑ 23 Nm
33 - Exhaust Pressure Sensor 2 - G451-
❑ Connected to the Auxiliary Fuel Pump - V393- bracket
ProCarManuals.com
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AG. Volkswagen AG d
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1.2.2 Overview - Particulate Filter with NOx Reduction Catalytic Converter, En‐
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5 - Control Line
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sition
G39-
❑ 52 Nm
❑ Use the Ring Wrench 7-
Piece Set - 3337- to
loosen and tighten.
052 112 A3- ; Hot Bolt
Paste - G 052 112 A3-
slots on the sensor body
9 - Seal
❑ Replace
10 - Clamp
❑ 7 Nm
❑ Replace
❑ -item 14- ⇒ Item 14 (page 272)
❑ 45 Nm

13 - Seal
❑ Replace
❑ Installing. Refer to
⇒ Fig. ““Install the Gasket Between Exhaust Door Control Unit -J883- and the NOx Reservoir or Slip
Catalyst”“ , page 378 .
14 - Clamp
❑ 7 Nm
❑ Replace
⇒ Fig. ““Installation Position of the Clamps Between Exhaust Door Control Unit -J883- and NOx Reservoir
or Slip Catalyst.”“ , page 378 .
15 - To Exhaust Door Control Unit - J883-
❑ -Item 4- ⇒ Item 4 (page 377)
16 - Oxygen Sensor after Three Way Catalytic Converter - G130-
❑ 52 Nm
❑ Use the Ring Wrench 7-Piece Set - 3337- to loosen and tighten.
❑ Grease only the threads with Hot Bolt Paste - G 052 112 A3- ; Hot Bolt Paste - G 052 112 A3- must not
get into the slots on the sensor body
17 - NOx Reduction Catalytic Converter
ProCarManuals.com
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26 - Nut tio
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❑ Fastened to cylinder block

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❑ After replacing, the ash load comparison adaptation must be set to “0”. Refer to Vehicle Diagnostic Tester
30 - Control Wire
❑ 45 Nm
31 - Bolt
❑ 9 Nm
32 - Bracket
❑ For the control line
33 - Bracket
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Exhaust Gas Temperature Sensor Installation Position

– Install the Exhaust gas temperature sensor so the angles are
maintained:
• Exhaust Gas Temperature Sensor 3 - G495- -1-: angle -23°-.
• Exhaust Gas Temperature Sensor 2 - G448- -1-: angle -30°-.
Engine Code CJAA
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♦ Wrench - Sw13 - T10384-

♦ Engine and Gearbox Jack - VAS6931-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta .2011
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♦ Overview - Exhaust Flap Control Module - J883- with Slip Cat‐
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VAS6340- are recommended for installing spring clips. p by
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Removing:
WARNING

space.
vacuum lines.
or hot components.

– Remove the intake hose -item 1- ⇒ Item 1 (page 336) between
the Mass Airflow Sensor - G70- and the intake scoop. Loosen
the spring clamps using the Hose Clip Pliers - VAS6362- .
– Disconnect the »orange« connector for the Exhaust Gas Tem‐
perature Sensor 2 - G448- -1- as well as the »black« connector
for the Heated Oxygen Sensor - G39- -3- on the plenum cham‐
ber bulkhead.

– Disconnect the »brown« connector for the Exhaust Gas Tem‐

perature Sensor 3 - G495- -1- (attached behind the bracket).
– Guide the wires out of the mount -2- on the plenum chamber
– Disconnect the connector -2- from the Exhaust Pressure Sen‐
sor 2 - G451- -1-.
– Remove the bolt -4- and remove the bracket -3- with Exhaust
Pressure Sensor 2 - G451- -1- in the direction of -arrow- and
set aside (control lines stay attached).
– Disconnect the control wire -item 5- ⇒ Item 5 (page 361) from
the Exhaust Pressure Sensor 1 - G450- . Loosen the spring
clamp using the Hose Clip Pliers - VAS6362- . Refer to
ProCarManuals.com

particulate filter remains connected). gen AG
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– Remove the noise insulation. Refer todb
y⇒V Body Exterior; Rep.
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– Remove the right drive axle heat
ss
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– Remove the right inner driveshaft from the transmission

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– Remove the lower bracket for the particulate filter. Refer to

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Remove the nuts above the bracket with the Wrench - Sw13 -
T10384- .
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⇒ Item 9 (page 399) .

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– Remove the particulate filter from the upper bracket and re‐
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move the bracket on the cylinder head. Refer to

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– Remove the nuts -arrows- and slightly pull the underbody cov‐
er downward.
Note
Route the cables as indicated. Refer to

⇒ “1.6 Exhaust System Component Line Routing”, page 378 .
ProCarManuals.com
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– Disconnect the »orange« connector for the Exhaust Gas Tem‐

perature Sensor 4 - G648- -1- as well as the »brown« con‐
nector for the Oxygen Sensor after Three Way Catalytic
Converter - G130- -3-.
– Disconnect from the bracket -2- and guide the lines out on the
underbody -arrows-.
– Remove the NOx reduction catalytic converter mounting on
the subframe. Refer to
– Lower the subframe approximately 6 cm. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Lowering . Volkswa AG. gen AG
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– Remove the Voltunnel brace. Refer to
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Vehicles with Engine Code CJAA

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converter, make sure it is not under stress.
clamps.

Caution

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– Install the particulate filter. Be careful of the electrical wires
t to the co
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ProCarManuals.com
– Install the subframe. Refer to ⇒ Suspension, Wheels and

Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .
ss o
– Install a new gasket between the NOx reduction catalytic con‐
cial p
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verter and the Exhaust Door Control Unit - J883- . Refer to
form
mer
⇒ Fig. ““Install the Gasket Between Exhaust Door Control Unit
atio
-J883- and the NOx Reservoir or Slip Catalyst”“ , page 378 .
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– Install the new clamp between the NOx reduction catalytic
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⇒ Fig. ““Installation Position of the Clamps Between Exhaust Door
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Control Unit -J883- and NOx Reservoir or Slip Catalyst.”“ , rig ht
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page 378 .
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Tightening specification. Refer to
Converter”, page 360 .
Vehicles with Engine Code CJAA
– Install the new seal between the NOx reduction catalytic con‐
verter and the particulate filter.
– Install the new clamp between the NOx reduction catalytic
converter and the particulate filter.
Make sure the clamp is in the correct installation position. Refer
to
⇒ “1.3 Clamps and Exhaust Gas Temperature Sensor Installed
Position”, page 368 .
Tightening specification -item 18- ⇒ Item 18 (page 366) .
– Install the tunnel brace:
• Tightening specification. Refer to
⇒ “1.7 Overview - Muffler”, page 381 .

The Additional Numbered Procedures Must Be Followed to En‐

sure the Particulate Filter with the NOx Reduction Catalytic Con‐
verter Is Installed without Tension:
Volkswagen AG
1. Position the lower bracket with the nuts on the cylinder blockagen
AG. does
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and on the particulate filter. (Do not tighten the nuts.)
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2. Position the new clamp with a new gasket between ho
ri the par‐ eo
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ticulate filter and turbocharger (do not tighten
ss a the clamp): ra
c
ce
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un
pt
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⇒ “1.3 Clamps and Exhaust Gas Temperature Sensor Instal‐
erm
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led Position”, page 368 .
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3. Install the EGR filter -item 9- ⇒ Item 9 (page 399) .
h re
ole,
spec
4. Position a new clamp between the particulate filter and EGR
filter (do not tighten the clamp):
t to the co
fer to
rrectne
⇒ “1.3 Clamps and Exhaust Gas Temperature Sensor Instal‐
led Position”, page 368 .
ss
5. Mount the particulate filter on the upper bracket but do not
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cial p
f
tighten the bolt yet.
inform
mer
– Tighten the mounting elements in the following sequence:
atio
m
ProCarManuals.com
6. NOx reduction catalytic converter mounting on the sub‐

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frame:
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7. Clamp between the particulate filter and turbocharger.

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8. Lower bracket to the cylinder block: yi

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9. Lower bracket to the particulate filter:
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10. Upper bracket to the particulate filter:
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11. Upper bracket to the cylinder head:
12. Clamp between the particulate filter and EGR filter:
• Tightening specification. Refer to
If the particulate filter was replaced:
– Remove the transport and protective packaging on the de‐
coupling element between the particulate filter and NOx re‐
duction catalytic converter.
lowing:
• Tightening Specifications. Refer to
alytic Converter”, page 360 , Particulate Filter with NOx Ab‐
sorption Catalyst - Overview

– Install the right inner driveshaft from the transmission flange.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 .
mission 02Q; Rep. Gr. 34 .
Transmission 02E; Rep. Gr. 34 . AG. Volkswagen AG d
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If the particulate filter was replaced, then the adaptation of the
un
pt
soot load measurement must be set to “0”. Refer to Vehicle Di‐
an
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agnostic Tester “Guided Functions”.
rm
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pe
ility
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– Perform a road test. The vehicle must be aligned if the steering
, is n
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wheel is »crooked«. Refer to ⇒ Suspension, Wheels, Steer‐
hole
spec
ing; Rep. Gr. 44 ; Wheel Alignment .
es, in part or in w
t to the co
rrectness of i
1.5 Overview - Exhaust Flap Control Module - J883- with Slip Catalyst
ProCarManuals.com
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1 - From the Reduction Cata‐

lytic Converter
2 - Seal
❑ Replace
❑ Installing. Refer to
⇒ Fig. ““Install the Gas‐
ket Between Exhaust
Door Control Unit -J883-
and the NOx Reservoir
or Slip Catalyst”“ ,
page 378 .
3 - Clamp AG. Volkswagen AG d
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❑ 7 Nm by
Vol not
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❑ Replace horis nte
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❑ Note the installation po‐ ss a ra
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⇒ Fig. ““Installation Po‐
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an
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ab
tween Exhaust Door
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Control Unit -J883- and
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NOx Reservoir or Slip
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Catalyst.”“ , page 378 .
ole,
spec
4 - Exhaust Door Control Unit -
t to the co
J883-
ProCarManuals.com

sition
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❑ Heat shield and connec‐
tor wire routing. Refer to
ss
⇒ “1.6 Exhaust System
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Component Line Rout‐
inform
ing”, page 378 .
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5 - Slip Catalyst
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❑ Exhaust System,
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Checking for Leaks. Re‐

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⇒ “1.10 Exhaust System, Checking for Leaks”, page 387 .

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7 - Clamping Sleeve p by
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❑ Note the installation position Refer to ⇒ Fig. ““Clamping Sleeve Installation Position”“ , page 378 .
agen
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❑ Align the exhaust system free of stress. Refer to

⇒ “1.9 Exhaust System, Installing without Tension”, page 385 .
❑ Tighten the bolted connections evenly
8 - Nut
❑ 23 Nm

AG. Volkswagen AG d
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Install the Gasket Between Exhaust Door Control Unit - J883- and
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– Insert the gasket -2- with the angled tab -B- in the notch -A-
ility
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on the NOx reservoir or slip catalyst -1-.
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– Insert the Exhaust Door Control Unit - J883- -3- with the re‐
hole
spec
taining tab -C- in the notch -A-.
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Installation Position of the Clamps Between Exhaust Door Control
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– Install the new clamp so the clamping bolt is opposite the Ex‐
on
c
haust Door Control Unit - J883- housing and the -45 ± 10°-
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ProCarManuals.com
AG.
Clamping Sleeve Installation Position

– When installing clamping sleeve, ensure that the bolt end
-arrow- does not project beyond the lower edge of clamping
sleeve:
• Threaded connection points toward the right.
• Tighten the threaded connections equally to 23 Nm.
1.6 Exhaust System Component Line Rout‐

ing
Routing Lines on the Exhaust Flap Control Module -J883-. Refer
to ⇒ page 378
Routing Lines for the Oxygen Sensor after Three Way Catalytic
Converter -G130- and Exhaust Gas Temperature Sensor 4 -
G648-. Refer to ⇒ page 379
Line Routing on the Exhaust Flap Control Module

1 - Slip Catalyst
2 - NOx Reduction Catalytic
Converter
3 - Direction of Travel
4 - Line
sition
5 - Cable Bracket
6 - Heat Shield
sition
7 - Exhaust Door Control Unit - AG. Volkswagen AG d
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8 - Exhaust Door Control Unit - orise nte
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Routing Lines for the Oxygen Sensor after Three Way Catalytic
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or
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1 - Oxygen Sensor after Cata‐

lytic Converter - G130-
2 - Cable Bracket
3 - Exhaust Gas Temperature
Sensor 4 - G648-
4 - Distance: 100 mm
5 - Line
❑ Note the installation po‐ agen
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1.7 Overview - Muffler

⇒ “1.7.1 Vehicles with Engine Code CBEA”, page 381
⇒ “1.7.2 Vehicles with Engine Code CJAA”, page 383
1.7.1 Vehicles with Engine Code CBEA
1 - Mounting Strap
❑ For the fuel tank
-item 10-
2 - Mount
3 - Bolt
❑ 23 Nm
❑ Replace
4 - Retaining Loop
5 - Center Muffler
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one unit withed the

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❑ Align the exhaust sys‐

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tem free of stress. Refer

to
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Installing without Ten‐

sion”, page 385 .
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❑ Exhaust System,
Checking for Leaks. Re‐
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⇒ “1.10 Exhaust Sys‐
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at
tem, Checking for

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Leaks”, page 387 .

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6 - Bolt
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❑ 23 Nm
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8 - Rear Muffler Prote
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❑ Original equipment as one unit with center muffler

❑ For repairs, replace each separately
❑ Exhaust System, Separating and Connecting. Refer to
⇒ “1.8 Exhaust System, Disconnecting and Connecting”, page 384 .
❑ Exhaust System, Checking for Leaks. Refer to
⇒ “1.10 Exhaust System, Checking for Leaks”, page 387 .

9 - Nut
❑ 23 Nm
10 - Repair Clamping Sleeve
❑ For replacing the center and rear muffler and/or exhaust pipe and rear muffler individually
⇒ Fig. ““Repair Clamping Sleeve Installation Position”“ , page 382 .
11 - Tunnel Brace
Repair Clamping Sleeve Installation Position

sleeve:
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1.7.2 Vehicles with Engine Code CJAA
1 - Mounting Strap
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❑ 23 Nm
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4 - Retaining Loop
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5 - Exhaust Pipe
6 - Bolt
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❑ 23 Nm
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7 - Mount
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8 - Rear Muffler
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❑ For repairs, replace

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❑ Exhaust System, Sepa‐ sd

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tem free of stress. Refer
to
Installing without Ten‐
sion”, page 385 .
❑ Exhaust System,
Checking for Leaks. Refer to ⇒ “1.10 Exhaust System, Checking for Leaks”, page 387 .
9 - Nut
❑ 23 Nm
10 - Repair Clamping Sleeve
❑ For individual replacement of exhaust pipe and rear mufflers
⇒ Fig. ““Repair Clamping Sleeve Installation Position”“ , page 384 .
11 - Tunnel Brace

Repair Clamping Sleeve Installation Position

sleeve:
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1.8 Exhaust System, Disconnecting and
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Connecting
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Note
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♦ A separating point has been provided in the connecting pipe
for removing, installing and individual replacement of the cen‐
ter or rear muffler.
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♦ The separating point is marked an indentation around the cir‐
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cumference of the exhaust pipe.

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♦ Pneumatic Body Saw - VAS6780- or
om
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c
♦ Chain Pipe Cutter - VAS6254-

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♦ Torque Wrench 1331 5-50Nm - VAG1331- (not illustrated)
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Procedure
WARNING
To prevent injuries from metal shavings, wear protective gog‐

gles and protective clothing.
– Cut the exhaust pipe at a right angle at the separating point

-arrow 2-, for example using a Pneumatic Body Saw -
VAS6780- or Chain Pipe Cutter - VAS6254- .
Connecting:
– Position the repair clamping sleeve at the side marks
-arrow 1 and 3- for installation.


sleeve:
• Tighten the threaded connections evenly.
Aligning Tail Pipes

– Align rear muffler so that the distance -a- between bumper cut-
out and tail pipes is uniform on left and right.
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1.9 Exhaust System, Installing without Ten‐
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Procedure
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– Loosen the threaded connections -3 and 4- on the clamping

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sleeve -1- between the slip catalyst -2- and the front muffler
(the -arrow- points in the direction of travel).
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– Align the clamping sleeve -1- to the marking -A- on the slip
rm
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catalyst -2-.
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• Dimension -a- = 5 mm
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• The connections must be at the right and must not project be‐
yond the lower edge of the clamping sleeve -arrow-.
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– Tighten the front connection
aut -3- on the clamping sleeve -1- by
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– Push the exhaust system as far as possible forward into the

double clamp until dimension -a- is reached on the retaining
loop (-arrow- points in direction of travel).
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• Dimension -a- 15 to 17 mm.

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– In this position, tighten the connections -3 and 4- on the clamp‐
ing sleeve -1- evenly.
– After tightening the clamping sleeve, check dimension -a- and
correct if necessary.

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Aligning Tail Pipes
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– Align rear muffler so that the distance -a- between bumper cut-
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out and tail pipes is uniform on left and right.
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1.10 Exhaust System, Checking for Leaks
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Test Sequence
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– Start the engine and let it run in idle.

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– Seal the tailpipes, for example with cloth or plug, for the dura‐
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tion of the leak test.
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– Check the connections in the exhaust system for leaks by lis‐
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– Repair the determined leaks.
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Prote AG.

2 Exhaust System, Engine Codes

CBDA, CBDB and CEGA
⇒ “2.1 Overview - Front Exhaust Pipe with Particulate Filter”, page
388
⇒ “2.2 Particulate Filter, Removing and Installing”, page 391
⇒ “2.3 Overview - Muffler”, page 395
⇒ “2.5 Exhaust System, Installing without Tension”, page 397
2.1 Overview - Front Exhaust Pipe with Par‐

ticulate Filter
Note
♦ Exhaust Manifold, Removing and installing. Refer to

♦ After exhaust system repairs, make sure exhaust system is
not under stress and that it has sufficient clearance from the
bodywork. If necessary, loosen the double clamp and align the
muffler and exhaust pipe so that sufficient clearance is main‐
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tained to the body and the mountings carry even loads.

♦ Replace the self-locking nuts.

♦ Ring Wrench 7-Piece Set - 3337-
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If the particulate filter of the Exhaust Pressure Sensor 2 - G451-

es, in part or in w
t to the co
is being replaced, the Exhaust Pressure Sensor 2 - G451- must

be adapted using the Vehicle Diagnostic Tester : Guided Func‐
tions, Adapt the Exhaust Pressure Sensor 2 - G451- .
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Rep. Gr.26 - Exhaust System, Emission Controls Prote
cted AG.
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- G451-
2 - 10 Nm
3 - Shield
G39-
❑ 50 Nm
052 112 A3- ; Hot Bolt
Paste - G 052 112 A3-
slots on the probe body
❑ To remove, use the Ring
Wrench 7-Piece Set -
3337-
5 - Exhaust Gas Temperature
Sensor 4 - G648-
❑ 45 Nm
❑ Coat the thread on the
sensor with Hot Bolt
Paste - G 052 112 A3-
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6 - Seal
❑ Replace
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7 - Clamp, 7 Nm d by ua
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8 - Exhaust Gas au
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Sensor 3 - G495-
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❑ 45 Nm
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❑ Coat the thread on the

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sensor with Hot Bolt

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Paste - G 052 112 A3-

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9 - 25 Nm
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10 - Mount
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2. Exhaust System, Engine Codes CBDA, CBDB and CEGA 389

Caution
and installing:
Do
10°.
Do
pling element.
Do
element.
Use
from stretching.
❑ With oxidation catalytic converter and front exhaust pipe

ProCarManuals.com
❑ After replacing, the adaptation of the soot load comparison must be set to “0” using the Vehicle Diagnostic
❑ Removing and installing. Refer to ⇒ “2.2 Particulate Filter, Removing and Installing”, page 391 .
12 - 25 Nm
13 - Bracket
❑ Bolted to the cylinder block
14 - Control wire, 45 Nm
15 - Bracket
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17 - Bracket
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❑ Attached to the cylinder head

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18 - 25 Nm
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20 - 25 Nm
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Clamping sleeve installation position

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– Position the double clamp at a distance -a- = 5 mm in front of

the marking on the front exhaust pipe for the particulate filter.
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Rep. Gr.26 - Exhaust System, Emission Controls Prote
cted AG.
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2.2 Particulate Filter, Removing and Instal‐

ling
Note
♦ Exhaust Manifold, Removing and installing. Refer to

♦ After exhaust system repairs, make sure exhaust system is
not under stress and that it has sufficient clearance from the
bodywork. If necessary, loosen the double clamp and align the
muffler and exhaust pipe so that sufficient clearance is main‐
tained to the body and the mountings carry even loads.
♦ Replace the self-locking nuts.
♦ If the particulate filter of the Exhaust Pressure Sensor 2 -
G451- is being replaced, the Exhaust Pressure Sensor 2 -
G451- must be adapted using the Vehicle Diagnostic Tester :
Guided Functions, Adapt the Exhaust Pressure Sensor 2 -
G451- .

♦ Hex Ball Socket - 3247-
ProCarManuals.com
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♦ Wrench - Sw13 - T10384-

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– Remove the battery and the rise
battery tray. Refer to ⇒ Electrical nte
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System; Rep. Gr. 27 ; Battery;
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Battery Tray, Removing and ra
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Installing . s
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– Disconnect the connector for the Heated Oxygen Sensor -

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G39- -3- as well as the connector for the Exhaust Gas Tem‐
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perature Sensor 4 - G648- -2-.

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Sensor 3 - G495- -1- (attached behind the bracket).

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– Disconnects form the retainers and guide the wires out of the
pr
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retainers on the plenum chamber bulkhead -2- and turbo‐

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– Disconnect the connector -1-, aremove

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– Lay the ExhaustaPressure
ut Sensor 2 - G451- on the particulate or
ac
filter. ss
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– Remove the screw -arrow- on the top bracket for the particu‐
late filter.
rrectness of i
– Remove the noise insulation. Refer to ⇒ Rep. Gr. 50 .
l purpos
– Remove the subframe with the steering gear. Refer to ⇒ Sus‐

pension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe
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with Hydraulic Steering Gear, Removing and Installing .

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– Loosen the clamp -1- between the particulate filter and the t. C rig
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– Remove the nuts above the particulate filter bracket using the Prote AG.
Wrench - Sw13 - T10384-
– Remove the nuts -arrows- on the particulate filter bracket -A-

from the crankcase. Leave the bracket on the crankcase.
FWD Vehicles:

– Remove the bolts -1- from the heat shield -A- above the right
axle shaft and remove the heat shield.
AWD vehicles:
– Remove the bolts -1- from the shield -1- above the right axle
shaft using a Hex Ball Socket - 3247- . Push the particulate
filter upward, if necessary, in order to be able to reach the rear
threaded connection.
– Loosen the clamp on the exhaust pipe. Leave it in its position.
ProCarManuals.com
– Remove the particulate filter bracket -A-.

– Slide the clamp toward the exhaust pipe.
Caution

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♦ Do not bend the decoupling element morethothan
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♦ Do not stretch the decoupling element.ss
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– Remove the particulate filter and exhaust pipe downward. Be

careful of the electrical wires and components.

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2.2.2 Installing
Caution

– Mount the particulate filter bracket on the crankcase and install

the nuts by hand.
– Mount the particulate filter on the bracket.
– Secure the exhaust pipe to the driveshaft or to the body.
– Install the screw on the particulate filter bracket by hand.
– Slide the double clamp into position on the exhaust pipe. agen
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– Guide the temperature sensor wires upward. ed by gu
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– Position the clamp on the turbocharger and tightenauit.
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– Tighten the screws in the following sequence:
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1. Lower particulate filter bracket to crankcase.
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2. Particulate filter to lower particulate filter bracket, use the
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Wrench - Sw13 - T10384- .
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3. Particulate filter to upper particulate filter bracket
hole
spec
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– Install the axle shaft heat shield with Hex Ball Socket - 3247- .
t to the co
– Mount the right axle shaft joint on the bevel box. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 .
rrectness of i
– Install the subframe with the steering gear. Refer to ⇒ Sus‐
l purpos
pension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe

with Hydraulic Steering Gear, Removing and Installing .
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– Install the suspended mounting for the exhaust pipe to the

subframe.
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– Tighten the double clamp on the exhaust system.

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2.3 Overview - Muffler

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Exhaust Pipe, Disconnecting. Refer to

f
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⇒ “2.4 Exhaust Pipe, Disconnecting”, page 396 .
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1 - 25 Nm
❑ Replace
2 - Retaining Ring
3 - Rear Muffler
4 - Mount
5 - 25 Nm
6 - Tunnel Brace
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hole
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2.4 Exhaust Pipe, Disconnecting

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– Disconnect the exhaust pipe at right angle at the separation

point -A-.
– During installation, position the repair double clamp at side
markings -B- .
♦ M8 = 25 Nm
♦ M10 = 40 Nm
2.5 Exhaust System, Installing without Ten‐

sion
• Engine must be cold. AG. Volkswagen AG d
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– Loosen the double clamp threaded connection
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catalytic converter and the front muffler.
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– Position the double clamp atssa distance -a- = 5 mm from the
a ra
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marking on the catalytic converter pipe and gently tighten the
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front threaded connection.
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– Push the rear muffler as far forward into the double clamp until
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dimension -a- reaches 15-17 mm between the suspended
ility
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mount/body and the suspended mount/rear muffler.
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The -arrow- points in the direction of travel.
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– Align rear muffler horizontally.
– Tighten the threaded connections of the double clamp in this
position. Tightening specification: 25 Nm.
rrectness of i
– After tightening the double clamp, check dimension -a- and
l purpos
correct if necessary.
nform
mercia
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2 - Connecting Pipe
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❑ For removing and instal‐

ling, also loosen the
connections -item 33-
⇒ Item 33 (page 273) on
the turbocharger
3 - To the Connection on the
Turbocharger
❑ -item 33-
4 - Seal
5 - Bolt
❑ 8 Nm
6 - Radiator
❑ For the EGR
7 - Nut
❑ 23 Nm
❑ Installed on the hex stud
bolt -item 17-
⇒ Item 17 (page 272) on
the turbocharger
8 - Control Line
❑ 23 Nm
gles of the control line
❑ To the Exhaust Pres‐

sure Sensor 1 - G450- .

Refer to ⇒ “1.2 Overview - Particulate Filter with NOx Reduction Catalytic Converter”, page 360 .
❑ To loosen at the housing -item 16- ⇒ Item 16 (page 399) remove the exhaust gas recirculation filter
9 - Filter
❑ For the EGR
10 - Nut
❑ 23 Nm
❑ Secure on the exhaust manifold with the heat shield -item 16- ⇒ Item 16 (page 272)
11 - To the Particulate Filter
12 - Clamp
❑ 3.5 Nm
❑ Replace
13 - Bolt
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17 - EGR Temperature Sensor - G98- , 20 Nm
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❑ EGR Temperature Sensor - G98- , Removing and installing. Refer to
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♦ EGR Temp. Sensor Socket - 14mm - T10401- (not illustrated)
Requirements
3. EGR System 399

Procedure
• Overview of vehicle from below:
Note
The coolant hoses indicated must be removed and moved to the

side to perform assembly work on the EGR Temperature Sensor
- G98- .
– Disconnect the coolant hoses from both connections

-arrow A- and -arrow D-.
– Lay aside both coolant hoses -arrows B and C- as illustrated.
• Assembly overview of engine compartment from above:
Caution
ProCarManuals.com

A- is disconnected:
– With the ignition switched off, disconnect the ground cable

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– Remove the air filter housing. Refer to d byV ua
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Note
ProCarManuals.com
Note the installation location of the lines and heat shield.
The illustration shows the EGR Temperature Sensor - G98- as

seen from the engine compartment looking out from the trans‐
mission side -arrow- below the brake master cylinder.
– Carefully guide the EGR Temp. Sensor Socket - 14mm -

T10401- onto the EGR Temperature Sensor - G98- with a
socket extension.
3. EGR System 401

– Make sure the cable from EGR Temperature Sensor - G98- is

guided in the groove of EGR Temp. Sensor Socket - 14mm -
T10401- -arrow A-.
– Loosen the EGR Temperature Sensor - G98- and remove it.
Install in Reverse Order of Removal. Note the Following:
Note
♦ EGR Temperature Sensor - G98- tightening specification, 20

Nm
♦ Cut out the gasket and replace if it is damaged or leaks
♦ Maintain the tightening specification.
Caution
Install the heat shield mats in their original locations.

Make sure the entire connection is seated securely.
Always replace the self-locking nuts, seals, gasketsageand
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ss Pliers - VAS6340-
are recommended for installing spring clips.
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4 EGR System, Engine Codes CBDA,

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Caution
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3 - 10 Nm
4 - To EGR Vacuum Regulator
Solenoid Valve - N18-
5 - Seal
❑ Replace
6 - Cable Guide
7 - Radiator
❑ For the EGR
❑ With a by-pass flap
8 - From Exhaust Manifold
9 - Connecting Pipe
10 - Vacuum Line
page 295 .
4. EGR System, Engine Codes CBDA, CBDB and CEGA 403

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5 Special Tools

equipment required
♦ Locating Pins - T10096-
♦ Wrench - Sw13 - T10384-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Engine/Gearbox Jack -
VAG1383A-
VAS6362-
♦ Tool Set 17 mm - T10395-
♦ Ring Spanner 7-Piece Set - agen
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mm - 3094-
5-50Nm - VAG1331-
VAS6208-
VAS6362-
♦ EGR Temp. Sensor Socket
- 14mm - T10401- (not illus‐
trated)
ProCarManuals.com
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♦ Body Saw - VAG1523B-
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28 – Ignition/Glow Plug System

1 Glow Plugs
⇒ “1.2 Glow Plug, Removing and Installing”, page 408
⇒ “1.3 Glow Plug Connectors, Removing and Installing”,
page 410
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♦ Glow Plug Socket - VAS6454-
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Removing:
Requirements
Procedure
Note
♦ When removing the glow plugs, make sure no contaminants

enter the fuel system and the glow plug duct.
408 Rep. Gr.28 - Ignition/Glow Plug System


⇒ Item 1 (page 312) .
-C-.
– Remove the fuel return line bolt -item 3- ⇒ Item 3 (page 312)
on the intake manifold.
Caution


410 .
ProCarManuals.com
sure reservoir).
gent).
– Dry the return line connections.
– Cover the return line connections with a cleaning cloth.
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– Remove the fuel return
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1. Glow Plugs 409

pressure fuel pump.
– Remove the fuel return lines -item 2- ⇒ Item 2 (page 312) and
lay them in front of the intake manifold.
– Remove the glow plug wiring guide and lay it aside.
Caution
♦ When cleaning the glow plug duct, make sure no contam‐

inants or cleaning solutions enter the connector contacts
on the glow plugs.
♦ Do not clean the connectors with cleaning solutions or
compressed air.
– Clean the glow plug duct in the cylinder head (contaminants

must not fall into the cylinder).
Note
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♦ Extract large contaminants with a vacuumedcleaner.
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• When installing the glow plugs, make sure no contaminants

enter the fuel system and the glow plug duct.
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• Only remove the sealing plugs right before installing the fuel
return lines.
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1.3 Glow Plug Connectors, Removing and

Installing
♦ Wheel Bolt Cap Pliers - 3314-

Removing:
Caution
Before removing the glow plug connectors, note that different

installation depths for the glow plugs in their respective cylin‐
ders.
– Position the Wheel Bolt Cap Pliers - 3314- with the groove
-arrow A- on the upper collar of the connector -arrow B- and
press together lightly.
Caution
Position the pliers so they do not touch or damage the cable.

Only use suitable tools.
Other unsuitable tools can damage the connector.
If the connector is damaged when removing it, replace the en‐
tire wiring harness including the connector (a connector cannot
be replaced separately).
ProCarManuals.com
– Pull the connector carefully off the glow plug in the direction of
the -arrow- using Wheel Bolt Cap Pliers - 3314- .
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Installing:
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– Guide the center terminal on the connector -arrow A- into the

glow plug socket -arrow B- by hand.
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1. Glow Plugs 411

– Press the glow plug connector -1- on by hand in direction of

-arrow- until it engages.
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2 Special Tools
AG. Volkswagen AG d
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♦ Wheel Bolt Cap Pliers - 3314-

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3 Revision History
DRUCK NUMBER: MEX5R009321
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
04.2 02/0 Lo‐ 113

Feedback # 1138155 - For Eric P.
015 5/20 cal 815
CJAA/CBEA added
16 Feed 5,
T10395A to remove G235.
back 114
Feedback 1142877 - add‐
s 287
ed steps to R&I right drive
7
axle in Particulate Filter
with NOx Absorption Cata‐
lytic Converter R&I
04.2 01/1 Lo‐ 114 Added procedure for CJAA Eric P.
015 5/20 cal 625 Oil pump R&I. Factory sent
15 Feed 8 (R&I.)
back
04.2 12/0 Lo‐ 113 Hiden Turbocharger with Eric P.
015 3/20 cal 815 exhaust manifold R&I not
15 Feed 8 for NAR
back
ProCarManuals.com
04.2 10/2 Lo‐ 112 Changed G505 to G451 to Eric P.

015 6/20 cal 165 match wiring diagrams.
15 Feed 4,
back 112 agen
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04.2 09/2 Lo‐ 112 Changed aut special tool p/n Eric P.
h
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015 2/20 cal 040 from VAG1318
ss to c
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15 Feed 3 VAS6551 in: 20, Fuel Sup‐

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Auxiliary Fuel Pump V393

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hole
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015 0/20 cal 810 40 to 15 Nm on water

es, in part or in w
15 Feed 7 & pump bolts

t to the co
back 118
108
04.2 07/0 Lo‐ 109 Removed special tool Eric P.
rrectness of i
015 8/20 cal 944 T40055 in chapter 17- Oil

l purpos
15 Feed 8 Supply Line to Turbo‐

back charger R&I
04.2 07/0 Lo‐ 110 Add specs: Target value in Eric P.
nf
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015 1/20 cal 846 30 seconds: 90 to 110 ml

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m
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15 Feed 7& (3.0 to 3.7 ounces). to 23-

om
back 110 Diesel Direct Injection Sys‐

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or c
856 tem - Fuel Pressure Regu‐

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04.2 06/1 Re‐ N/A Reformat book to current Eric P.

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04.2 05/1 Fac‐ N/A Factory Update Eric P.
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15 Up‐
date


Edi‐ tion ck d By
tion
02.2 04/1 LF 109 Updated Cylinder Head Eric P.
014 7/20 044 Gasket ID (2 places) w/ in‐
15 2 fo from 5K1 CJAA engine
per factory.
02.2 12/1 LF 106 20 Fuel Supply, current Eric P.
014 8/20 668 draw checking, changed
14 0 G6 to V393 disconnecting
connector. AG. Volkswagen AG d
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02.2 11/0 Cor‐ Removed fluid bcapacities
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02.2 10/2 LF 105 Addedsnew step and Illus‐ Eric P.
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014 2/20 240 tration/graphic.

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4 Cylinder Diesel Engine 2.0L Engine Common Rail Repair Manual Edition 04.2015 PDF

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E80109914

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.4 Pendulum Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.7 Engine Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2 Sealing Flange and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1 Overview - Sealing Flange and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.2 Crankshaft Sealing Flange, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.3 Crankshaft Seal, Replacing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.4 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 64

2.5 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.3 Bearing Shells - Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3.5 Piston Projection in Top Dead Center (TDC), Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.3 Needle Bearings, Removing and Installing from Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 75

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2.2 Camshafts, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.2 Engine Oil, Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

2 Lubrication System Components, Engine Code CBEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2.2 Oil Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

6 Fuel Supply System, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

3.1 Overview - Turbocharger with Exhaust Manifold and Attachments . . . . . . . . . . . . . . . . . . 270

4 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

4.2 Overview - Charge Air Cooler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

4.4 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

4.5 Vacuum Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

4.7 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.4 Fuel Injector (Piezo Injector), Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

3.5 Fuel Pressure Regulator Valve N276 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

3.7 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

3.16 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

3.17 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

4 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Vehicles Except Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Except Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

4 EGR System, Engine Codes CBDA, CBDB and CEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

00 – General, Technical Data

1.1 Engine Number

the toothed belt guard.

♦ The first part (maximum four letters) represents the “engine

produced, the first of the six characters is replaced with a letter.

Codes CBEA CJAA

1) with a sulfur content less than 15 mg/kg of diesel fuel

2 Rep. Gr.00 - General, Technical Data

1.1 Engine, Removing olkswage

partment, pay attention to the following due to the limited

♦ Route all lines and wires in their original locations.

lines, coolant and refrigerant lines, brake fluid lines and

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-