VW Scirocco 2008-2015 - 4-Cyl. Injection Engine (2.0l Engine, Turbocharger) VW R GMBH (CDLA CDLC CDLK)

Service
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B80465DB3

Scirocco 2015 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Securing engine on engine and gearbox support . . . w. a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. d. o.e. . . . . . . . . . . 12
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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . .by. V. o.l . . . . . . . . . . . . . . . . . . . . . n.o.t g. u.a. . . . . . 14
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2 Assembly mountings . . . . . . . . . . . . . . . .th.or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee.o. . 16
2.1 Assembly overview - assembly mountings au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c 16
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.4 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1.5 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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3.4 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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3.5 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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Scirocco 2015 ➤
1.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.6 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing oilepressure AG. Volksw switch
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2.3 Removing and installing olkswoil filter housing . . . .e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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2.4 Checking oil pressurerise
d and oil pressure switch . . . . .a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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3 Oil circuit s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . 98
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3.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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4.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 117

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2.6 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 118
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3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.4 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii Contents
Scirocco 2015 ➤
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Schematic overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.3 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Releasing high pressure in fuel system agen . . . . . . . . . . .A.G.d.o.es. . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - fuelhorail ris with injectors . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . 147
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2.2 Removing and installing ss
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2.3 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
es, in part or in w
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.3 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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4.4 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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5.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . at 166

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5.4 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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6 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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6.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 171
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7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.5 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.7 Checking exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Contents iii
Scirocco 2015 ➤
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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iv Contents
Scirocco 2015 ➤
00 – Technical data
1 Safety information
(VRL013459; Edition 09.2019)
⇒ “1.1 Safety precautions when working on the cooling system”,
page 1
⇒ “1.2 Safety precautions when working on ignition system”, page
1
⇒ “1.3 Safety measures when working on fuel supply”,
page 2
⇒ “1.4 Safety measures when working on vehicles with a start/
stop system”, page 2
⇒ “1.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
1.1 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
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1.2 autho Safety precautions when working on ignition system
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Risk of injury due to electric shock
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The ignition system is under high voltage when the engine is run‐
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– Do not touch or disconnect ignition cables when the engine is

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running or being turned at starter speed.

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Risk of damage to components

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Connecting or disconnecting electric cables or washing the en‐

gine while it is running may damage components.
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– Switch off the ignition before connecting or disconnecting elec‐

tric cables.
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– Switch off the ignition before washing the engine.

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1. Safety information 1
Scirocco 2015 ➤
1.3 Safety measures when working on fuel supply

Danger of accident when fuel is under high pressure
The fuel system is pressurised. Injury from fuel spray possible.
– Release high pressure in fuel system before opening fuel sys‐
tem.
Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
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– Disconnect voltage supply to fuel pump before
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1.4 Safety measures when working on vehicles with a start/stop system
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If the vehicle’s start/stop system is activated, the engine can start
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unexpectedly. A message in the dash panel insert indicates
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whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
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1.5 Safety precautions when using testers and measuring instruments during
inform
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a road test
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Risk of injury caused by unsecured testing and measuring instru‐

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– Secure testing and measuring instruments on the rear seat.
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– Have a second person operate the test and measuring equip‐

ment on the rear seat.
2 Rep. gr.00 - Technical data

Scirocco 2015 ➤
2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

The engine number (“code letters” and “serial number”) can be
found on the left on the joint between the engine and the gearbox.
The engine code is also stamped on the right side of the cylinder
head and on the cylinder block.
The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 3 characters) makes up the “engine
code”, and the second part (6 characters), the “serial number”. If
more than 999,999 engines were produced with the same code
letters, the first of the six digits is replaced by a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
Vehicles with four digit engine codes
Starting with the letter “C”, new four digit engine codes have been
introduced. The first 3 places show the mechanical design of en‐
gine and are stamped on the engine as previously. The fourth digit
denotes the performance and torque rating of the engine and de‐
pends on the engine control unit. The four-digit engine code can
be found on the identification plate, the vehicle data sticker and
the engine control unit.
Engine code CDLA CDLC CDLK
Manufactured 11.09 ► 11.09 ► 05.14 ►
Exhaust emissions fulfil EU 5 EU 5 EU 6
Displacement 1984 1984 1984 AG. Volkswagen AG d
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Power kW at rpm 195/6000 188/6000 d b 206/6000
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Torque Nm at 350/2500 330/2400
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rpm … 5000 …ss 5200 … 5000 c
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Bore ∅ mm 82.5 82.5 82.5

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Stroke mm 92.8 92.8 92.8

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Compression ratio 9.8 9.8 9.8

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Valves per cylinder 4 4 4

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RON 98 unlea‐ 98 unlea‐ 98 unlea‐

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ded1 ded1 ded1

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Injection, ignition Motronic Motronic Motronic

MED 9.1 MED 9.1 MED 9.1
Type of mixture formation Homoge‐ Homoge‐ Homoge‐
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neous neous neous

Knock control 2 sensors 2 sensors 2 sensors
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Lambda regulation 2 probes 2 probes 2 probes

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Catalytic converter Yes Yes Yes

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Camshaft timing adjust‐ Yes Yes Yes

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Electronic power control Yes Yes Yes

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1) Also 95 RON with reduced power

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2. Identification 3
Scirocco 2015 ➤
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 Foreign objects in engine”, page 4
⇒ “3.3 Contact corrosion”, page 4
⇒ “3.4 Routing and attachment of lines”, page 4
⇒ “3.5 Fitting radiator and condensers”, page 5
⇒ “3.6 Checking vacuum system”, page 5
3.1 Rules for cleanliness

Even small degrees of soiling can lead to defects. Therefore,
comply with the following rules for cleanliness when working on
the fuel supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface. Cover with lint-free
cloths only.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been stored outside their packaging (e.g. in tool boxes).
♦ When the system is open, do not work with compressed
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♦ Make sure that no fuel gets onto the fuel rhoses.
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♦ Protect disconnected electrical connectors from dirt and water,
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and reconnect them only when dry.

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3.2 Foreign objects in engine

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

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engine, seal open channels of the intake and exhaust sections

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with suitable bungs, for example from the engine bung set -
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VAS 6122- .
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3.3 Contact corrosion

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Contact corrosion can occur if non-approved fasteners are used

on the vehicle (bolts, nuts, washers etc.).
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For this reason, only connecting elements with a special surface

coating have been fitted.
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Furthermore, rubber and plastic components as well as adhe‐

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If there is any doubt about the suitability of parts, a general rule

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is to use new parts ⇒ Electronic Parts Catalogue (ETKA) .

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3.4 Routing and attachment of lines

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♦ Mark fuel lines, vacuum lines, lines for activated charcoal filter
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installed in the original positions and correctly connected. If
necessary, take a photo or make a sketch.
4 Rep. gr.00 - Technical data

Scirocco 2015 ➤
4-cylinder injection engine
age(2.0
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♦ To avoid damaging ris
edpipes and wires, ensure adequate clear‐
b ran
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ance from all moving
utho or hot components in the engine com‐ or
partment onssaccount of the confined space.
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3.5 nl
Fitting radiator and condensers
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Even if installed correctly, the radiator, the condenser and the
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charge air cooler may have small dents in their fins. This does not
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mean that these components have been damaged. It is not per‐
, is n
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missible to renew radiators, condensers or charge air coolers only
hole
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because of such minor dents.
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3.6 Checking vacuum system
Special tools and workshop equipment required
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♦ Hand operated vacuum pump - VAS 6213-
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Procedure
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve
to relevant component.
– If a fault has been entered in the event memory, make sure to
check not only all vacuum lines leading to the specified com‐
ponent, but also those leading to other components.
– If pressure cannot be built-up using hand vacuum pump - VAS
6213- or pressure immediately drops again, check hand vac‐
uum pump and connecting hoses for leaks.
3. Repair instructions 5
Scirocco 2015 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 6
⇒ “1.2 Securing engine on engine and gearbox support”,
page 12
⇒ “1.3 Installing engine”, page 14
1.1 Removing engine
Special tools and workshop

equipment required
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♦ Torque wrench - V.A.G 1331-

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♦ Torque wrench - V.A.G 1332- t. C rig
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♦ Engine and gearbox jack - V.A.G 1383 A-
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♦ Pliers for spring-type clips - VAS 5024A-
♦ Stepladder - VAS 5085-
♦ Engine support - T10012-
♦ Cable tie
6 Rep. gr.10 - Removing and installing engine

Scirocco 2015 ➤
Procedure
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable ties which were opened or cut when the engine was
removed must be replaced with new cable ties in the same
positions when engine is installed.
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions. gen AG
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♦ Ensure that there is sufficient clearancedb
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– Remove air filter housing ⇒ page 155 .

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– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
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Removing and installing battery .
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– Unscrew bolts -arrows-.
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– Remove battery tray.
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– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
plenum chamber cover .
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– Disconnect engine wiring harness from engine control unit -
J623- .
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– Release feed-through for engine wiring harness -arrow-, and
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pull it off upwards.
1. Removing and installing engine 7

Scirocco 2015 ➤
– Slide the two clips in the direction of the -arrows- and remove
cover from electronics box in engine compartment.
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– Unscrew cable from alternator -A- and cable from battery -B-
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– Unscrew nut -arrow-.

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– Remove earth wire from longitudinal member.

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– Open cable duct latches on longitudinal member -arrows-.

Scirocco 2015 ➤
– Free electrical connector -1- and disconnect.

– Open wiring guide bracket located below -2-.
– Remove wiring harness leading to engine control unit - J623-
from wiring duct, and place it on engine.
WARNING
Fuel supply line is pressurised. Wear protective goggles and

protective clothing to avoid injury and contact with the skin.
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– Disconnect breather line -1- and fuel feed liness-2-.
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– Separate breather line -2- and pull activated charcoal filter with
hoses upwards out of bracket.
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– Remove noise insulation ⇒ General body repairs, exterior;

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Rep. gr. 66 ; Noise insulation; Removing and installing noise
a
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insulation .
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– Remove front right and front left wheel housing liners ⇒ Gen‐
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Removing and installing front wheel housing liner .
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– Remove charge air hoses -arrows-.

Scirocco 2015 ➤
– Remove heat shield for drive shaft on right side -arrows-.

– Remove right and left drive shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
– Remove front exhaust pipe with catalytic converter
⇒ page 179 . wage es n
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– Move lock carrier to service positionris ⇒ General body repairs,
ed nte
exterior; Rep. gr. 50 ; Lock carrier;
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Moving lock carrier to and eo
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back from service position . ss c
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– Drain coolant ⇒ page 107 .
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Risk of freezing injury from refrigerant
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When working on the air conditioning system, there is a risk of
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highly pressurised refrigerant escaping from the system. There is
spec
a risk of injury to the skin and parts of the body due to freezing.
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– Wear protective gloves.
– Wear protective goggles.
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– Extract refrigerant, and open the refrigerant circuit immediate‐
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– If more than 10 minutes have passed since the refrigerant was
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extracted, repeat the extraction process before opening the

refrigerant circuit. Due to continued evaporation, pressure will
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build up in the refrigerant circuit.
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– Extract refrigerant using air conditioner service station .
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– Unscrew bolt -arrow-.
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– Detach refrigerant line from air conditioner compressor.
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– Remove refrigerant line from condenser.

Scirocco 2015 ➤
– Unscrew bolts -1 to 3-.

– Remove pendulum support.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and gearbox and move to one side.
– Disconnect all connection, coolant, vacuum and intake hoses
from engine.
Vehicles with manual gearbox
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism; Removing and installing selector mech‐
anism .
– Clamp-off hose for pipe/hose line -A- to slave cylinder using

hose clips - 3094- .
– Pull out clip -arrow- for pipe/hose line to stop.
– Pull pipe/hose line out of slave cylinder breather.
Caution
Do not depress clutch pedal any longer.
Vehicles with DSG® AG. Volkswagen AG d

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– Remove selector cable from gearboxby⇒V Rep. gr. 34 ; Selector
o l
gu
ara
mechanism; Removing and installingrised
selector lever cable . nte
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s c
– Release mechatronic unit connector
s -arrow-.
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Continued for all vehicles:

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– Unscrew coolant circulation pump - V50- -arrows-.

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Scirocco 2015 ➤ AG. Volkswagen AG d
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4-cylinder injection engineVo(2.0
lksw l engine, turbocharger)
oes
Volkswagen
not R GmbH - Edition 09.2019
y gu
db ara
ise nte
– Insert engine bracket - T10012-
tho
r
in engine and gearbox jack - eo
V.A.G 1383 A- . s au ra
c
s
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le
– Fit engine bracket - T10012- to engine as shown, and tighten
un
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d
bolt -1- and nut -2- to approx. 20 Nm. itte
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ab
– Lift engine and gearbox slightly using engine and gearbox jack
ility
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- V.A.G 1383 A- .
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Prote AG.
Note
♦ When removing, use the stepladder - VAS 5085- .

♦ Engine and gearbox must be guided carefully when lowering
to prevent damage to bodywork.
– Carefully lower engine with gearbox.
1.2 Securing engine on engine and gearbox support

Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
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d by ara
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♦ Lifting tackle - 2024 A- p by
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♦ Workshop hoist - VAS 6100- Prote AG.
♦ Engine and gearbox support - VAS 6095-

Procedure
Secure engine on engine and gearbox support - VAS 6095- to
carry out repairs.
– Unbolt gearbox.

Scirocco 2015 ➤
4-cylinder injection engine (2.0 l. Vengine,
olkswageturbocharger) Volkswagen R GmbH - Edition 09.2019
AG n AG d
agen oes
o lksw not
– Attach lifting tackle - 2024 d by V A- as follows and lift from engine gu
ar
and gearbox jack - oVAS ris
e
6100- using workshop crane - V.A.Gantee
1383 A- . au
th or
ac
ss
Belt pulley end: 2nd hole in hook rail at position 1
ce
e
nl
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Flywheel end: 1st hole in hook rail at position 7
itte
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Caution
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Use securing pins on hooks and locking pins to avoid damage
spec
es, in part or in w
to engine and vehicle.
t to the co
♦ The positions marked 1…4 on the bar must face towards the
rrectness of i
V-belt pulley end.
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♦ The holes in the hook rails are counted up from the hook.
– Secure engine to engine and gearbox support - VAS 6095- .
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1.3 Installing engine
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Procedure
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Install in reverse order of removal, observing the following:

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Caution C py
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When doing any repair work, especially in the engine compart‐
c by lksw
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ment, pay attention to the following due to the cramped condi‐ Prote AG.
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– Insert new dowel sleeves in the cylinder block for centring the
engine and gearbox.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
– Lightly grease input shaft splines with grease - G 000 100- .
– Check clutch and clutch mechanism, and install them ⇒ Rep.
gr. 30 ; Clutch mechanism; Repairing clutch release mecha‐
nism .
Vehicles with DSG®
– Renewing needle bearing in crankshaft ⇒ page 36 .
Continued for all vehicles
– When installing the engine and gearbox assembly, make sure
there is sufficient clearance to the subframe and radiator.
– Align engine mountings as follows:

Scirocco 2015 ➤
♦ There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
– Install pendulum support.
– Install right and left drive shafts ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive
shaft .
– Install front exhaust pipe with catalytic converter
⇒ page 179 .
– Screw on refrigerant lines.
– Install selector mechanism, and adjust it if necessary ⇒ Rep.
gr. 34 ; Selector mechanism; Removing and installing selector
mechanism .
– Reconnect pipe/hose assembly to slave cylinder breather.
Vehicles with DSG®
– Install selector lever cable, and adjust it if necessary ⇒ Rep.
gr. 34 ; Selector mechanism; Removing and installing selector
lever cable .
Continued for all vehicles:
– Install noise insulation n⇒
AGGeneral
. Volkswagbody
en AG repairs, exterior; Rep.
lkswage
gr. 66 ; NoiseVinsulation; Removing
d es
andoinstalling
not noise insu‐
o gu
lation . ed b y ara
n
is tee
or
– Installautplenum
h
chamber cover ⇒ General body repairs,
or exte‐
ac
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
ss
ce
le
plenum chamber cover .

un
pt
an
d
itte
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐

y li
rm
ab
moving and installing battery .

pe
ility
ot
wit
– Add coolant ⇒ page 107 .

, is n
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hole
– Connect ⇒ Vehicle diagnostic tester.

spec
es, in part or in w
– Read event memory, and delete all entries which may have
t to the co
occurred due to repair work.

– Carry out road test.
rrectness of i
– Then carry out vehicle system test and rectify any faults which
l purpos
have occurred.
nform
ercia
Note
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com
tion in
The readiness code must be generated if the event memory has

r
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been cleared ⇒ Vehicle diagnostic tester .

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Specified torques:
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Bolted connection Specified torque
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Nuts and bolts M6 10 Nm
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AG.
15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm

Scirocco 2015 ➤
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 16
2.1 Assembly overview - assembly mount‐

ings
Engine mounting
Component Specified torque
Bolt -A- 20 Nm + 90° 1)
Bolt -B- 40 Nm + 90° 1)
G. Volkswagen AG d
Bolt -C- 60 Nm + 90° 1)agen A oes
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1) db ara
Renew after each removal ris
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Gearbox mounting
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Bolt -1- 40 Nm + 90° 1)
ility
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Bolt -2- 60 Nm + 90° 1)
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spec
1) Renew after each removal
es, in part or in w
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Pendulum support
nform
ercia

m
at
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Bolt -A- 40 Nm + 90° 1)

ion
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Bolt -B- 100 Nm + 90° 1)

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Bolt pendulum support to gearbox and then to subframe.
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1) Renew after each removal

AG. Volkswagen AG d
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Scirocco 2015 ➤
ris
4-cylinder
ut
ho injection engine (2.0 l engine, turbocharger)
eo
ra
Volkswagen R GmbH - Edition 09.2019
s a c
s
ce
le
un
13 – Crankshaft group
pt
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1 Cylinder block (pulley end)
wit
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⇒ “1.1 Assembly overview - poly V-belt drive”, page 17
spec
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
t to the co
19
⇒ “1.3 Removing and installing poly-V belt”, page 19
rrectne
⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”,
page 21
ss o
cial p
f
⇒ “1.5 Removing and installing sealing flange on pulley end”,
inform
page 23
mer
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1.1 Assembly overview - poly V-belt drive

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1 - Ancillary bracket
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❑ Observe tightening se‐

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❑ Qty. 2 Prote
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agen
❑ 23 Nm
3 - Nuts
❑ Qty. 2
❑ 23 Nm
4 - Alternator
❑ Removing and installing
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
Removing and installing
alternator
❑ To facilitate attachment
of alternator, knock
back threaded bushes
for alternator securing
bolts slightly.
5 - Bolts
quence ⇒ page 18
❑ 40 Nm
6 - Bushes
❑ Qty. 2
7 - Bolts
❑ 25 Nm
8 - Air conditioner compressor
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air
conditioner compressor; Removing and installing air conditioner compressor
9 - Poly V-belt
❑ Mark direction of rotation with chalk or felt pen before removing.
❑ Check for wear
1. Cylinder block (pulley end) 17

AG. Volkswagen AG d
agen oes
ksw not
Scirocco 2015 ➤ by Vol
gu
ara
d
orise Volkswagen R GmbH - Edition 09.2019
nte
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❑ Do not kink ss c
ce
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❑ Removing and installing ⇒ page 19
un
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10 - Pulley
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❑ Renew after removal
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spec
❑ 20 Nm +90°
t to the co
12 - Bolts
❑ 23 Nm
rrectne
13 - Tensioner
❑ Swing with open-end spanner to slacken poly V-belt.
ss o
cial p
f inform
Bolt-tightening sequence for ancillary bracket
mer
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18 Rep. gr.13 - Crankshaft group

Scirocco 2015 ➤
1.2 Assembly overview - sealing flange, belt pulley end
1 - Bolt
❑ Do not oil
❑ Use counterhold - 3415-
to loosen and tighten.
❑ 90 Nm +90°
2 - Crankshaft pulley
❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in one
position
3 - Bolts
❑ 15 Nm
4 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Renewing ⇒ page 21
5 - Sealing flange
❑ Must seat on dowel
pins.
⇒ page 23
6 - Cylinder block
7 - Bolts
AG. Volkswagen AG d
❑ Renew after removal agen oes
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❑ 60 Nm +90° rised b ara
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8 - Flywheel/drive plate aut ra
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flywheel ⇒ page 30
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❑ Removing and installing drive plate ⇒ page 31

erm
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9 - Adapter
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❑ Must seat on dowel sleeves.

hole
spec
❑ Do not damage or bend when assembling.

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10 - Sealing flange with oil seal

❑ Renew only as complete unit
rrectness of i

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11 - Diamond-coated washer
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1.3 Removing and installing poly-V belt

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Prote AG.
1. Cylinder block (pulley end)
Scirocco 2015 ➤
♦ Locking pin - T10060A-
AG. Volkswagen AG d
agen oes
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insulation .
ility
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– Mark running direction of poly V-belt.
h re
ole,
spec
– Unlock activated charcoal filter and pull upwards out of bracket
with lines connected -arrow-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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i
or
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te
sd
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– Swivel tensioning element in direction of -arrow-.

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pyri by
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co lksw
by
cted agen
Prote AG.
– Use the locking pin - T10060A- to lock the tensioning element

in place.
– Remove poly V-belt.
Installing
Note
♦ When fitting poly V-belt, check direction of belt rotation and

proper seating of belt in belt pulleys.
♦ Fit poly V-belt over air conditioner compressor last.

AG. Volkswagen AG d
agen oesScirocco 2015 ➤
olksw not
yV gu
ed b Volkswagen R GmbH - Edition
ara 09.2019
nte
ris
ho eo
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On completion of work, always start engine and
ss a check belt run‐ c
ning.
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le
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1.4 Renewing crankshaft oil seal - belt pulley end
s o
cial p
f inform
mer
atio
m
equipment required
o
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fo
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Seal puller - 3203-

♦ Counter-hold - 3415-
♦ Assembly tool - T10053-

Scirocco 2015 ➤
Removing
– Remove toothed belt ⇒ page 55 .
– Lock toothed belt pulley using counterhold - 3415- .
– Remove crankshaft pulley.
– To guide seal extractor - 3203- , screw centre bolt into crank‐

shaft to stop by hand.
– Unscrew inner part of oil seal extractor - 3203- 9 turns (approx.
20 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor - 3203- , place it

in position and, exerting firm pressure, screw it into the oil seal
as far as possible.
– Loosen knurled screw and turn inner part against crankshaft
agen
AG. Volkswagen AG d
oes
until the oil seal is pulled out. yV
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Install in reverse order of removal, observing
ss the following:
ce
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nl
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– Remove oil residues from crankshaft journal with a clean cloth.

du
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itte
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ility
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– Fit guide sleeve - T10053/1- onto crankshaft journal.

hole
spec
– Slide dry oil seal over guide sleeve onto crankshaft journal.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen
olksw
R GmbH - Edition 09.2019
AG. V agen AG
agen does
lksw not
– Using assembly tool - T10053- and bolt - T10053/2-
db
y V , press in
o gu
ara
seal as far as stop. rise nte
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Note
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♦ Contact surface between pulley, diamond-coated washer and
rm
ab
pe
ility
crankshaft must be free of oil.
ot
wit
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♦ Renew the centre bolt after each removal.
h re
hole
spec
♦ Thread and shoulder must be free of oil and grease.
es, in part or in w
t to the co
– Fit toothed belt pulley -2- with diamond-coated washer -3-.
rrectness of i
– Tighten bolt -1- hand-tight.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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fo
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– Tighten new central bolt.
AG.
Specified torques
♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,
page 19
♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54
1.5 Removing and installing sealing flange on pulley end

Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ce
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nl
pt
du
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ility
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spec
es, in part or in w
t to the co

rrectness of i

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♦ Hand drill with plastic brush

♦ Silicone sealant - D 176 404 A2-
nform
ercia
♦ Scraper
m
at
om
io
Removing
n
c
in t
or
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– Turn crankshaft back slightly.

for
en
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t.
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Cop py
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rig ht
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Prote AG.

Scirocco 2015 ➤

– Remove crankshaft pulley.
– Remove sump ⇒ page 86 .
– Unbolt sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer. Volkswa AG. gen AG
agen does
– Remove sealant residues from cylinder block witholka
swflat scra‐ not
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– Cover oil seal with a clean cloth. aut ra
c
ss
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nl
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du
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Note
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ility
If seal is to be renewed, drive it out as follows:
ot p
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hole
spec
– Remove residual sealant on sealing flange using a rotating
es, in part or in w
plastic brush (wear eye protection).
t to the co
– Clean sealing surfaces. They must be oil and grease-free.
Installing
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
riv
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

p
cum
for
3 mm).
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ng
t.
yi Co
op
– Apply sealant bead of about 2…3 mm as shown -arrows- to
C py
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clean sealing surface of sealing flange.
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note
♦ Before applying sealant bead, cover sealing ring with a clean

cloth.
♦ The sealant bead must be no thicker than 2 to 3 mm. Other‐
wise excess sealant may get into the sump and block the
strainer in the oil intake pipe.
♦ Observe use-by-date of sealant.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ Use the guide sleeve - T10053/1- to fit the sealing flange with
seal installed.
♦ Leave the sealant to dry for approx. 30 minutes after assem‐
bly. Only then fill with engine oil.

Scirocco 2015 ➤
– Fit sealing flange immediately and lightly tighten all bolts

-arrows-.
– Tighten sealing flange bolts diagonally and alternately.
– Remove excess sealant.
– Install sump ⇒ page 86 .
– Install oil seal if necessary ⇒ page 21 .
Note
♦ Contact surface between pulley, diamond-coated washer and

crankshaft must be free of oil.
♦ The centre bolt must be renewed.
♦ Thread and shoulder must be free of oil and grease.
AG. Volkswagen AG d
agen oes
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– Fit toothed belt pulley -2- with diamond-coated byV
ol
washer -3-. not
gu
ara
ed
is nte
– Tighten bolt -1- hand-tight. hor eo
aut ra
ss c
ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Tighten new central bolt.
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Specified torques
nform
ercia
♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,

page 19
m
at
om
io

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in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Scirocco 2015 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 27
⇒ “2.2 Removing and installing sealing flange on gearbox side”,
page 28
⇒ “2.3 Removing and installing flywheel”, page 30
⇒ “2.4 Removing and installing drive plate”, page 31
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ Do not oil
❑ 90 Nm +90°
❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in one
position
3 - Bolts
❑ 15 Nm
4 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip. AG. Volkswagen AG d
agen oes
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❑ Renewing ⇒ page 21 byV
ol not
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5 - Sealing flange hor eo
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❑ Must seat on dowel ss c
pins.
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⇒ page 23
erm
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6 - Cylinder block
wit
is n
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7 - Bolts
ole,
spec

t to the co
❑ 60 Nm +90°
8 - Flywheel/drive plate
rrectne

flywheel ⇒ page 30
ss
❑ Removing and installing drive plate ⇒ page 31

o
cial p
f in
9 - Adapter
form
mer
❑ Must seat on dowel sleeves.

atio
om
❑ Do not damage or bend when assembling.

n
c
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10 - Sealing flange with oil seal

t
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❑ Renew only as complete unit

um
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fo
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Cop py
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rig ht
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co Vo
by lksw
27
cted agen
Prote AG.
2. Cylinder block, gearbox end
Scirocco 2015 ➤
AG. Volkswagen AG d
agen oes
ksw
2.2 Removing and installing sealing flange ol not
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on gearbox side ris nte
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Special tools and workshop equipment required s
ce
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un
pt
♦ Guide piece - T10122/6- or guide piece - T10122/6A- from fit‐
an
d
itte
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ting tool - T10122B- or fitting tool - T10122C-
erm
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ility
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wit
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spec
t to the co
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cial p
f inform
mer
♦ Assembly aid - T10122/1- from fitting tool - T10122B- or fitting
atio
tool - T10122C-
om
n
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te
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Cop py
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Prote AG.
♦ Hand drill with plastic brush attachment

♦ Safety glasses
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove flywheel ⇒ page 30 .
– Detach intermediate plate from sealing flange and dowel pins
-arrows-.

n AG. Volkswagen AG do Scirocco 2015 ➤
wage
4-cylinder injection engine (2.0 l engine, Vturbocharger)
olks Volkswagen eRs nGmbH
ot g - Edition 09.2019
y ua
db ran
rise tee
– Unscrew bolts -1 … 8-. tho or
s au ac
– Remove sealing flange. s
ce
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un
pt
an
d
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erm
ab
ility
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wit
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spec
t to the co
rrectne
Installing
ss
o
cial p
f inform
– In order to prevent the lubrication system from being soiled,
mer
cover the open section of the sump with a clean cloth.
atio
om
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WARNING
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Risk of eye injury.

fo
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♦ Wear safety goggles. t. Cop py
rig
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cted
– Remove sealant residue.
agen
Prote AG.
– Clean sealing surfaces.
Note
Observe use-by date of silicone sealant.

2 mm).
– Apply silicone sealant -arrow- to clean sealing surface of seal‐

ing flange.
• Thickness of sealant bead: 2 to 3 mm.
2. Cylinder block, gearbox end 29

Scirocco 2015 ➤
Note
♦ Check sealing flange; it must be free of kinks and damage.

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

edges.
– Attach assembly aid - T10122/1- -A- to guide - T10122/6-
-B-.
– Push sealing flange -C-, with outer side leading, onto guide
piece - T10122/6- -B-.
– Remove assembly aid -A-.
AG. Volkswagen AG d
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– Put guide -A- with sealing flange -B- onto crankshaft journal.
h re
hole
spec
es, in part or in w
t to the co
Note
It is not necessary to tighten the bolts -arrows-.

rrectness of i
l purpos
– Push sealing flange -B- over guide -A- onto crankshaft journal.
– Remove guide -A-.
nform
ercia
• After installing the sealing flange, wait about 30 minutes for

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

at
om
ion
c
Specified torques
in t
or
his
ate
♦ ⇒ page 27
do
priv
cum
for
en
ng
2.3 Removing and installing flywheel

t.
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Cop py
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Prote AG.

Scirocco 2015 ➤
Removing
Caution
The dual-mass flywheel may be destroyed if the bolts -B-are

unscrewed with a pneumatic nut runner or impact wrench.
Unscrew dual-mass flywheel bolts by hand, without application
agen
AG. Volkswagen AG d
of any tools. V olksw
oes
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ho
ut or
– Rotate dual-mass flywheel -A- so that bolts
ss a-B- align centrally ac
with the holes -arrows-.
ce
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un
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an
d
– When removing bolts -B-, make sure that screw heads do not
itte
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jam on flywheel.
rm
ab
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Insert counterhold - 3067- in hole on cylinder block.

– Mark position of flywheel in relation to engine.
nform
ercia
– Unscrew flywheel.
m
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Installing
n in
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Specified torques
fo
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t.
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♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page Cop py
27
t. rig
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Prote AG.
2.4 Removing and installing drive plate


Scirocco 2015 ➤
♦ Counter-hold - VW 558-
♦ Depth gauge
♦ Hexagon bolt M8 × 45 and two M10 hexagon nuts
Removing
– Secure counterhold - VW 558- to drive plate with hexagon bolt
M8 x 45. When doing this, insert two M10 hexagon nuts in
between counterhold and drive plate to act as spacers.
Installation position of counterhold: -A- to loosen, -B- to tighten.
Installing
– Fit drive plate using ring with recesses -1-.

– Fit bolts -3-, and tighten them to 30 Nm.
AG. Volkswagen AG d
agen oes
olksw not
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pt
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erm
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wit
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hole
spec
– Check dimension -a- at three points and calculate average.

es, in part or in w
t to the co
Specification: 19.5…21.1 mm
rrectness of i
Note
l purpos
Measure through hole in drive plate to milled surface of cylinder

block.
nf
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orm
If specification is not attained:

m
atio
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n in
or c
thi
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f
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t.
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Cop py
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by lksw
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32
Prote AG.
Rep. gr.13 - Crankshaft group
Scirocco 2015 ➤
– Remove drive plate again and fit shim -2-. Again tighten bolts
-3- to 30 Nm.
– Then, tighten bolts to specified torque.
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
27
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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spec
es, in part or in w
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Cop py
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by lksw
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Prote AG.

Scirocco 2015 ➤
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 34
⇒ “3.2 Crankshaft dimensions”, page 35
⇒ “3.3 Allocation of main bearing shells”, page 35
⇒ “3.4 Removing and installing sender wheel”, page 36
⇒ “3.5 Renewing needle bearing in crankshaft”, page 36
3.1 Assembly overview - crankshaft
Note
♦ Before removing the crankshaft, prepare a suitable surface for storing the crankshaft so that it is not placed
down on the sender wheel ⇒ Item 4 (page 34) and the sender wheel is not damaged.
♦ Secure engine to engine and gearbox support - VAS 6095- to carry out repairs.
1 - Bolts
❑ Threaded along com‐
plete length.
❑ Only tighten to 65 Nm
when measuring crank‐
shaft radial clearance;
do not turn further.
❑ 65 Nm +90°
2 - Bearing cap
AG. Volkswagen AG d
❑ Bearing cap 1: obelt agen
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❑ Bearing ut
hoshell
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retaining eo
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and bearing caps must
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align.
du
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3 - Bolts
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wit
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❑ 10 Nm +90°
h re
hole
spec
4 - Sender wheel
es, in part or in w
t to the co
❑ For engine speed send‐

er - G28-
❑ Always renew sender
rrectness of i
wheel if securing bolts

have been unscrewed
l purpos
❑ Can only be installed in

one position (holes are
nf
ercia
offset).
orm
m

atio
om
⇒ page 36
n in
or c
thi
e
5 - Crankshaft
t
sd
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❑ Axial clearance, new:

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0.07…0.23 mm; wear

f
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limit: 0.30 mm
Co
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❑ Check radial clearance using Plastigage; new: 0.017 … 0.037 mm; wear limit: 0.07 mm
opyri
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❑ Do not rotate crankshaft when checking radial clearance by c lksw

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Prote AG.

Scirocco 2015 ➤
❑ Crankshaft dimensions ⇒ page 35 .
❑ Removing and installing needle bearing ⇒ page 36
6 - Thrust washers
❑ For bearing 3
7 - Bearing shell for cylinder block
❑ With oil groove.
❑ Classification for ordering spare parts ⇒ page 35 .
❑ Do not interchange used bearing shells (mark).
8 - Sprocket
❑ For oil pump drive.
9 - Bearing shell for bearing cap
❑ Without oil groove.
❑ Do not interchange used bearing shells (mark).
3.2 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Crankshaft Conrod
sion main journal ∅ journal ∅
Basic dimension 54.00 -0.017 47.80 -0.022
-0.037
agen AG. Volkswagen AG d -0.042
oes
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Stage I 53.75 Vol -0.017 47.55 -0.022 gu
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Stage II ss a 53.50 -0.017 47.30 -0.022 ra
c
-0.037 -0.042
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Stage III 53.25 -0.017 47.05 -0.022

an
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-0.037 -0.042
rm
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3.3 Allocation of main bearing shells

wit
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hole
Upper bearing shells of the proper thickness are allocated to the

spec
cylinder block in the factory. Coloured dots are used to identify

es, in part or in w
t to the co
the thickness of the bearing shells.

Letters on the lower sealing surface of the cylinder block indicate
which bearing thickness is to be used at each position.
rrectness of i
G = yellow
l purpos
B = blue
nform
ercia
W = white
m
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Note
r
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♦ Arrow points in direction of travel.

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♦ If the coloured marks are no longer legible, use blue bearing

n
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op
shells. C py
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♦ Lower crankshaft bearing shells with “yellow” coloured marks
op Vo
by c lksw
are always supplied as spare parts. cted agen
Prote AG.
3. Crankshaft 35
Scirocco 2015 ➤
3.4 Removing and installing sender wheel

Removing
– Always renew sender wheel -2- each time bolts -1- are loos‐
ened.
Note
♦ The second time the countersunk head bolts are tightened, the
contact points in the sender wheel for the countersunk heads
are deformed so far that the bolt head -arrows- seats on the
crankshaft -3-, and the sender wheel is loose under the bolt.
♦ Sender wheel can only be installed in one position. The holes
are offset.
Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 34
3.5 Renewing needle bearing in crankshaft

Only vehicles with a dual clutch gearbox
♦ Puller - T10055-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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aut ra
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nl
♦ Centring mandrel - 3176-

pt
du
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itte
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erm
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ot p
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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n in
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thi
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t.
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Cop py
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Prote AG.

Scirocco 2015 ➤
♦ or drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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♦ Puller, e.g. KUKKO - 21/2- s
ce
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pt
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Pull out needle bearing using commercially available puller,
nf
ercia
e.g. KUKKO - 21/2- -arrow-, adapter - T10055/3- and puller -
orm
T10055- .
m
atio
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n in
Installing
or c
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Note
Co
Cop py
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The lettering on the needle bearing must be legible when instal‐
p by
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led. Prote
cted AG.
agen
– Drive in needle bearing using drift - VW 207 C- or centring

mandrel - 3176- .
3. Crankshaft 37
Scirocco 2015 ➤
Installation depth: dimension -a- = 2 mm.
lkswage es n
o ot g
byV ua
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tho
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spec
es, in part or in w
t to the co
rrectness of i
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t.
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Cop py
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co lksw
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38
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Prote AG.
Rep. gr.13 - Crankshaft group
Scirocco 2015 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 39
⇒ “4.2 Separating new conrod”, page 40
⇒ “4.3 Checking pistons and cylinder bores”, page 41
4.1 Assembly overview - pistons and conrods
1 - Conrod bolt
❑ Oil threads and contact
surface
❑ To measure radial clear‐
ance, tighten to 30 Nm
but not further.
❑ 45 Nm +90°
2 - Bolt
❑ with pressure relief
valve
❑ Opening pressure:
1.3…1.6 bar
❑ 27 Nm
3 - Oil spray jet
❑ For piston cooling
4 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Due to the cracking AG. Volkswagen AG d
method used to sepa‐ agen oes
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rate the bearingedcap by gu
ara
from the conrod horis in man‐ nte
eo
ufacture, the
s a caps only
ut ra
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fit in one sposition and
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only on the appropriate

nl
pt
du
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conrod.
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❑ Mark cylinder number

ility
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-B-
wit
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❑ Installation position:
h re
hole
markings -A- face to‐

spec
wards belt pulley end.

es, in part or in w
t to the co
5 - Bearing shell
❑ Note installation position ⇒ page 40
rrectness of i
❑ Do not interchange used bearing shells.

l purpos
❑ Axial clearance, new: 0.10…0.35 mm; wear limit: 0.4 mm

❑ Check radial clearance with Plastigage: new: 0.02…0.06 mm, wear limit: 0.09 mm. Do not rotate crank‐
shaft when checking radial clearance.
nf
ercia
orm
6 - Connecting rod
m
atio
om
❑ With industrially cracked conrod cap.

n in
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thi
❑ Renew as set only.

te
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❑ Mark cylinder number -B-

r
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f
❑ Installation position: markings -A- face towards belt pulley end.

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op
❑ Separating new conrod ⇒ page 40 . C py
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Prote AG.
4. Pistons and conrods 39

Scirocco 2015 ➤
7 - Retaining ring
8 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .
9 - Piston AG. Volkswagen AG d
agen oes
❑ Checking ⇒ page 42 olksw not
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d by ara
❑ Mark installation position and cylinder number.
orise nte
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aut
❑ Arrow on piston crown points to belt pulley end. ra
ss c
❑ Install using piston ring clamp.
ce
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nl
pt
du
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❑ Checking cylinder bores ⇒ page 42 .
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ab
10 - Piston rings
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❑ Offset gaps by 120°
wit
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❑ Use piston ring pliers to remove and install.
hole
spec
❑ Marking faces to piston crown
es, in part or in w
t to the co
❑ Checking ring gap ⇒ page 41 .
❑ Checking ring-to-groove clearance ⇒ page 41 .
rrectness of i
l purpos
Installation position of bearing shells

– Position bearing shells in centre of conrod and conrod bearing
nf
ercia
o
cap when fitting.
rm
m
atio
m
Distance -a- must be identical on both sides.

o
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Piston and cylinder dimensions
thi
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sd
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Caution
f
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t.
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op py
The cylinder bore may not be worked on (reboring, honing,
t. C rig
gh ht
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grinding) may not be carried out using workshop tools! This will p by
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damage the surface of the cylinder bore.
lksw
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Prote AG.
Piston ∅ Cylinder bore ∅

Basic dimension mm 82.465 1) 82.51
1)Dimensions without graphite coating (thickness 0.02 mm). The
graphite coating wears away.
4.2 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark which cylinder the conrod belongs to ⇒ page 39 .

Scirocco 2015 ➤
– Clamp conrod in a vice with aluminium vice clamps.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

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

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

♦ Feeler gauge
♦ Micrometre 75 - 100 mm - VAS 6071-
♦ Cylinder gauge - VAS 6078- n AG. Volkswagen AG do
lkswage es n
Checking piston ring gap byV
o ot g
ua
d ran
ir se tee
– Push ring squarely fromuth above down into cylinder bore to ap‐
o
or
prox. 15 mm from sbottom
s a end of cylinder. ac
ce
e
nl
Piston ring Ring gap

pt
du
an
itte
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New Wear limit

erm
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ility
Compression rings mm 0.20 … 0.40 0.8

ot p
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Oil scraper ring mm 0.25 … 0.50 0.8

h re
hole
spec
es, in part or in w
Checking ring-to-groove clearance

t to the co
– Clean annular groove before check.

rrectness of i
Piston ring Clearance

New Wear limit
l purpos
Compression rings mm 0.06 … 0.09 0.20

nform
ercia
Oil scraper ring mm 0.03 … 0.06 0.15

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Pistons and conrods 41

Scirocco 2015 ➤
Checking piston
Volkswagen AG
– Measure pistons approx 10 mm from the lower edge aof
genskirt,
AG. does
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at 90° to the piston pin axis. by
Vol not
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ara
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se nte
Deviation from nominal dimension: max. 0.04
tho mm
ri eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
rrectness of i
– Deviation from nominal dimension: max. 0.08 mm
l purpos
nform
ercia
Note
m
a
com
Do not measure cylinder bores when cylinder block is mounted
tion in
on a repair stand with engine and gearbox support - VAS 6095- ,
r
te o
thi
as measurements may then be incorrect.
s
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do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.

Scirocco 2015 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 43
⇒ “1.2 Removing and installing cylinder head”, page 45
⇒ “1.3 Removing and installing cylinder head cover”, page 50
⇒ “1.4 Checking compression”, page 51
1.1 Assembly overview - cylinder head
Note
♦ If an exchange cylinder head is installed, all the contact surfaces between the supporting elements, roller
rocker fingers and the running surfaces of the cam must be oiled before the cylinder head cover is installed.
♦ Do not remove the plastic packing pieces for protecting the open valves until immediately before fitting
cylinder head.
♦ If the cylinder head is renewed, the coolant must also be completely changed.
1 - Bolts agen
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quence ⇒ page 50 rised
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❑ 10 Nm aut ra
c
ss
2 - Cylinder head cover
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⇒ page 50
erm
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ility
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3 - Seal
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❑ Renew if damaged or
ole,
leaking
spec
t to the co
4 - Valve
❑ For crankcase ventila‐
tion. rrectne
5 - Cap
s
6 - Seal
s o
cial p
inform
leaking
mer
atio
m
7 - Bolts
o
n
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i
or
❑ 4 Nm
thi
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8 - Seal
i
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leaking
Co
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9 - Vacuum pump rig ht
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10 - Bolt
cted agen
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❑ 4 Nm
11 - Inlet camshaft control
valve 1 - N205-
⇒ page 75
1. Cylinder head 43
Scirocco 2015 ➤
12 - Seal
13 - Bolt
❑ 10 Nm
14 - Cable bracket
15 - Seal . Volkswagen AG
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❑ Renew if damaged or leaking Volkswa not
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16 - Bolts rise nte
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❑ 10 Nm au ra
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ss
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17 - Housing
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18 - Seal
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19 - Transportation shackle
h re
hole
spec
20 - Bolt
es, in part or in w
❑ 25 Nm
t to the co
21 - Stud
❑ For intake manifold
rrectness of i
❑ 10 Nm
l purpos
22 - Partition
nform
ercia
23 - Cylinder head gasket

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ion
❑ Observe installation position: part number faces cylinder head
c
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or
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te
24 - Bolt
a
do
priv
❑ 10 Nm
um
for
en
ng
t.
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25 - Hall sender - G40-
Co
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26 - Seal
ht
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27 - Stud
cted agen
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❑ For tensioning roller
❑ 10 Nm
28 - Stud
❑ For exhaust manifold
❑ 20 Nm
29 - Cylinder head
❑ Check for distortion ⇒ page 45 .
30 - Cylinder head bolt
❑ Observe sequence for loosing and tightening ⇒ page 45
❑ 40 Nm +180°
44 Rep. gr.15 - Cylinder head, valve gear

Scirocco 2015 ➤
Checking cylinder head for distortion

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

equipment required
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es, in part or in w
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♦ Drip tray - V.A.G 1306- or drip tray for workshop hoist - VAS
6208-
♦ Puller - T40039-
♦ Insert tool - T10070-
1. Cylinder head 45
Scirocco 2015 ➤

AG. Volkswagen AG d
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When doing anyut
h repair work, especially in the engine compart‐
or eo
ment, pay attention to the following due to the cramped condi‐
a ra
ss c
tions:
ce
le
un
pt
an
d
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
itte
y li
vated charcoal filter system, coolant and refrigerant, brake
rm
ab
pe
fluid and vacuum) and electrical wiring in their original po‐
ility
ot
sitions.
wit
, is n
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hole
♦ To avoid damage to lines, ensure sufficient clearance to
spec
all moving or hot components.
es, in part or in w
t to the co
Removing
rrectness of i
• The engine must be no more than warm to touch.
l purpos
Note
nform
mercia
♦ All cable ties which were opened or cut during removal must
a
com
tio
be renewed at the same points.
n in
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♦ If engine oil is dirty, change oil.
s
iva
do
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rp
cum
fo
– With ignition switched off, disconnect battery earth strap ⇒

en
ng
t.
yi
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
Co
op py
connecting battery .
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ht ht
rig by
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– Remove plenum chamber bulkhead ⇒ General body repairs,
co lksw
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cted agen
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐
Prote AG.
num chamber bulkhead .
– Remove intake manifold ⇒ page 158 .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Remove front exhaust pipe with catalytic converter
⇒ page 179 .
– Release clip -arrow-.
– Pull charge air hose off charge air cooler.

Scirocco 2015 ➤

– Remove charge air pipe.
– Pull off or disconnect all other electrical connections from tur‐
bocharger and lay to side.
– Unscrew oil supply line and coolant supply line from turbo‐ . Volkswag
en AG
charger -arrows-. ksw
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ab
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wit
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spec
t to the co
– Remove oil return line from turbocharger.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
sd
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pr
cum
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t.
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– Unscrew bolts -1 and 2-. t. Cop py
rig
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yri
– Remove turbocharger support. p by
co Vo
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cted agen
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Prote AG.
Removing and installing battery .
1. Cylinder head 47
Scirocco 2015 ➤

– Remove battery tray.
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spec
t to the co
rrectnes
– Loosen clamps -1 and 2-.
s o
cial p
f in
– Pull off coolant hoses.
form
mer
– Pull off or disconnect all the other electrical connections as
atio
m
necessary from the cylinder head and lay open.

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t. rig
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– Move wiring harness aside.

– Remove coolant hose.
– Remove poly V-belt ⇒ page 19 .
– Remove locking pin - T10060A- from tensioning device for
poly V-belt.
– Remove cylinder head cover ⇒ page 50 .

Scirocco 2015 ➤
4-cylinder injection engine (2.0 l engine,wturbocharger)
agen Volkswagen
AG. Volkswagen AG
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– Observe correct sequence when rloosening
ise
d cylinder head nte
bolts. tho eo
au ra
c
ss
ce
le
un
pt
Note
an
d
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rm
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Check if all hose and line connections between engine, gearbox
pe
ility
ot
and body have been detached.
wit
, is n
h re
hole
spec
– Remove cylinder head.
es, in part or in w
t to the co
Installing
rrectness of i
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Note
♦ There must be no oil or coolant in the cylinder head bolt pock‐
nform
ercia
ets in the cylinder head.

m
a
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ti
♦ Do not remove new cylinder head gasket from packaging until
on in
it is ready to be fitted.
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♦ Handle new gasket very carefully. Damage will cause leakage.
do
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t.
– Place clean cloths in cylinders so that no dirt or emery cloth op
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particles can get in between cylinder wall and piston.
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– Also prevent dirt and emery cloth particles from getting into
op Vo
by c lksw
coolant.
cted agen
Prote AG.
– Carefully clean sealing surfaces of cylinder head and cylinder

block. Ensure that surfaces are not scored or scratched (if
abrasive paper is used, do not use a grade less than 100).
– Carefully remove metal particles, emery residue and cloths.
– If crankshaft has since been turned, position cylinder number
1 piston to TDC and then turn crankshaft back slightly.
– Position new cylinder head gasket; inscription (Part No.) must
be legible.
– Note centring pins in cylinder block -arrows-.

– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
1. Cylinder head 49
Scirocco 2015 ➤
– Tighten cylinder head in sequence as follows:

Stage Specified torque
1 40 Nm
2 Turn 90° further
3 Turn 90° further
– Fill with new coolant ⇒ page 107 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 43
♦ ⇒ “4.1 Assembly overview - intake manifold”, page 157
♦ ⇒ “1.1 Assembly overview - silencers”, page 177
1.3 Removing and installing cylinder agenhead

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Special tools and workshop equipment
s a required
u ra
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s
ce
♦ Pliers for spring-type clips - VAS 5024 A-
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
♦ Puller - T40039-
ercia
orm
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n in
or c
thi
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sd
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f
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t.
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Cop py
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pyri by
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Removing
– Remove air filter ⇒ page 155 .

Scirocco 2015 ➤
AG. Volkswagen AG d
– Unscrew bolts -arrows-. ksw
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spec
es, in part or in w
t to the co
– Disconnect lines -2, 3 and 4- from cylinder head cover.
rrectness of i
– Disconnect electrical connectors -1-.
l purpos
– Remove ignition coils ⇒ page 186 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
– Unscrew line for crankcase breather system with heat shield
t. rig
gh ht
yri
from turbocharger -1-.
p by
co Vo
by lksw
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– Pull off activated charcoal filter line to turbocharger from cyl‐
AG.
inder head cover -2-.

– Loosen cylinder head cover working from inside outwards.
– Remove cylinder head cover.
Installing
– Tighten cylinder head cover - in several stages - in the tight‐

ening sequence shown.
– Ensure that upper toothed belt guard is seated correctly.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 43
1.4 Checking compression
1. Cylinder head 51
Scirocco 2015 ➤

equipment required
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nl
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du
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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ate
do
priv
cum
for
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t.
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Cop py
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rig ht
py by
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♦ Spark plug socket - 3122 B-

♦ Puller - T40039-
♦ Compression tester - V.A.G 1763-
♦ Adapter - V.A.G 1381/5A-
Test conditions
• The engine oil temperature must be at least 30°C.
• Voltage supply OK.
Procedure
– Remove ignition coils ⇒ page 186 .
– Remove spark plugs using spark plug socket and extension -
3122 B- .
– Check compression using compression tester - V.A.G 1763-
and adapter - V.A.G 1381/5A- .

Scirocco 2015 ➤
Note
Using the compression tester ⇒ Operating instructions
– Have starter actuated by a second mechanic.

– Operate starter until tester shows no further pressure in‐
crease.
Compression pressures:
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New bar pressure byV
o Wear limit bar pres‐ Difference
l ot g
ua between
ir se
d sure cylindersrabar
nte pres‐
utho sure e or
a ac
ss
11.0 … 14.0 7.0 max. 3.0
ce
e
nl
pt
du
an
– After completing work, read event memory of engine control
itte
y li
unit, clear all entries which may have been created during
erm
ab
ility
checks and repairs ⇒ Vehicle diagnostic tester.
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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co lksw
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1. Cylinder head 53
Scirocco 2015 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 54
⇒ “2.2 Removing and installing toothed belt”, page 55
2.1 Assembly overview - toothed belt
1 - Bolt
❑ 10 Nm
2 - Toothed belt guard
3 - Bolt
❑ Renew after removal lkswage es n
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❑ Use counterhold - 3036- ir se
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tee
to loosen and tighten. utho
or
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❑ 50 Nm +180° ss
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un
pt
4 - Camshaft sprocket
an
d
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❑ Locked in installation
erm
ab
position by Woodruff
ility
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key.
wit
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5 - Bolt
spec
❑ Install with locking fluid
t to the co
❑ 10 Nm
rrectne
7 - Woodruff key
s
❑ Check for firm seating
s o
cial p
f
8 - Nut
inform
mer
❑ 25 Nm
atio
m
9 - Tensioning pulley
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❑ Semi-automatic
te
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10 - Coolant pump
p
cum
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ng

t.
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⇒ page 115 Cop py
t. rig
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11 - O-ring p by
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12 - Bolt
❑ 25 Nm
13 - Roller
14 - Bolts
❑ 15 Nm
15 - Bolt
❑ 35 Nm
16 - Roller
17 - Sealing flange
❑ Assembly overview ⇒ page 19

Scirocco 2015 ➤
❑ Contact surface between pulley, diamond-coated washer and crankshaft must be free of oil.
❑ Can only be fitted in one position
20 - Bolt
❑ Do not oil
❑ Use counterhold - 3415- to loosen and tighten.
❑ 90 Nm +90°
21 - Toothed belt
❑ Mark direction of rotation with chalk or felt pen before removing.
❑ Check for wear
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23 - Bolts yV
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❑ Qty. 7 o
ir se
ran
tee
th or
❑ 8 Nm au ac
ss
ce
e
24 - Engine support
nl
pt
du
an
itte
25 - Bolt
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erm
ab
❑ 45 Nm
ility
ot p
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, is n
h re
hole
spec
2.2 Removing and installing toothed belt
es, in part or in w
Special tools and workshop equipment required t to the co
♦ Bracket - T10339-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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priv
cum
for
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♦ Adapter - 10 - 222 A /18-
co Vo
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2. Toothed belt drive 55

Scirocco 2015 ➤
♦ Support bracket - 10 - 222 A-
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♦ Adapter - 10 - 222 A /8- ss
ce
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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Removing
nform
ercia

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tion in
WARNING
r
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thi
s
iva
do
♦ Fuel supply line is pressurised. Wear protective goggles
r
rp
cum
fo
and protective clothing to avoid injury and contact with the en

ng
t.
skin. Wrap a cloth around the connection before loosening
yi Co
op py
hose connections. Then release pressure by carefully t. C rig
gh ht
pulling hose off connection. yri
p by
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cted
♦ For reasons of safety, before opening the fuel system, re‐
agen
Prote AG.
move fuse for the fuel pump control unit - J538- from the
fuse holder. This prevents the fuel pump from being acti‐
vated by driver door contact switch. Fuse assignment
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
– Disconnect breather line -1- and fuel feed line -2-.

Scirocco 2015 ➤
– Separate breather line -arrow 2- and pull activated charcoal

filter -A- with hoses upwards out of bracket.
WARNING
Hot steam may escape when expansion tank is opened. Wear

eye protection and protective clothing to avoid eye injuries and
scalding. Cover the cap with a cloth and open it carefully.
– Depressurise by opening coolant expansion tank and closing

it again.
– Loosen clamp -arrow-, and pull off coolant hose.

– Collect escaping coolant with a cloth.
– Disconnect electrical connector -1-.

– Lay coolant expansion tank to one side.
– Remove poly V-belt ⇒ page 19 . AG. Volkswagen AG d
agen oes
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h
aut ra
ss c
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un
pt
an
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erm
ab
ility
ot p
– Remove tensioner for poly V-belt -A-.

wit
is n
h re
– Secure bracket - T10339- at the two upper threaded holes.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤
– Position support bracket - 10 - 222 A- with adapter - 10 - 222

A /8- and adapter - 10 - 222 A /18- on longitudinal members.
AG. Volkswagen AG d
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
– Remove toothed belt cover.
h re
hole
spec
es, in part or in w

insulation . t to the co

rrectness of i

l purpos
nf
ercia
orm
m
atio
m

o
n in
or c
thi
e
– Remove charge air pipe together with hoses.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Set camshaft pulley to “TDC” marking by turning crankshaft.

– The mark on the camshaft toothed-belt pulley must align with
the arrow on the toothed-belt guard.

Scirocco 2015 ➤
– Remove vibration damper/belt pulley.
Note
♦ Ensure that the TDC markings align before removing the vi‐
bration damper.
♦ Do not turn the crankshaft until the TDC position is additionally
marked.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Mark TDC position -arrow-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
– Unscrew bolt -3-.

c
in t
or
his
ate
do
priv
Note
um
for
en
ng
t.
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op
The following work step is necessary to raise the engine high C py
t. rig
enough.
gh ht
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co lksw
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Prote AG.

Scirocco 2015 ➤
– Unscrew bolts -2 and 3-.

– Remove assembly mounting completely.
Caution
When raising engine using support bracket - 10 - 222 A- , en‐

sure that no components or hoses are damaged, over-exten‐
ded or torn off.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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– Lift engine
ss a together with support bracket - 10 - 222 A- . c
ce
le

un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes

s o
cial p
f in
– Remove toothed belt cover downwards from engine.

form
mer
– Remove engine bracket upwards from engine.

atio
om
n
c
– Mark direction of rotation of toothed belt.

i
or
n thi
te
sd
a
– Loosen tensioning roller and remove toothed belt.

iv
o
pr
cum
r
fo
– Turn crankshaft back slightly.

en
ng
t.
yi Co
op
Installing C py
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p by
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Prote AG.
Note
♦ Never rotate the camshaft when the crankshaft is at TDC (risk

of damage to valves/piston crowns).
♦ The engine must be no more than warm to touch.

Scirocco 2015 ➤
– Set camshaft and crankshaft to TDC markings.

– Fit toothed belt on crankshaft toothed belt pulley (note direc‐
tion of rotation).
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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– Fit toothed belt in the sequence: tensioning roller, camshaft
ss
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pulley, coolant pump and last onto guide roller -arrow-.
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Ensure proper seating of tensioning roller in cylinder head.
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– Tension toothed belt; to do this, turn Allen key to right

-direction of arrow- until notch is positioned above lug (toothed
belt over-tensioned).
– Relax toothed belt again.
– Tension toothed belt until notch and lug are positioned oppo‐
site each other.
– Tighten nut.
– Turn crankshaft 2 turns in engine direction of rotation until en‐
gine is again at TDC. It is important that the last 45° rotation
(1/8 turn) is performed without interruption.
– Check toothed belt tension. Specification: indicator and notch
must align.

Scirocco 2015 ➤
– Check valve timing; the markings must align -arrows-.

If the markings do not align:
– Repeat valve timing adjustment.
If the markings align:
– Bring engine bracket to installation position.
– Install toothed belt cover from below.
– Install vibration damper. AG. Volkswagen AG d
agen oes
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– Check valve timing; the markings must align -arrows-.ss c
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– Tighten both upper bolts of toothed belt guard -arrows-.
s o
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– Attach engine bracket to cylinder block and tighten bolts hand-
form
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– Lower engine with support bracket - 10 - 222 A- .

– Tighten bolt -3-.
– Tighten bolts -1 and 2-.
– Install engine assembly mounting.

Scirocco 2015 ➤
– Tighten bolts for engine assembly mounting and engine brack‐

et hand-tight -arrows-; to do so, bring surfaces into contact
using support bracket - 10 - 222 A- .
Align engine mountings as follows:

There must be a distance -a- of at least 10 mm between engine
support and longitudinal member (right side).
The side surface of the engine support -2- should be located par‐
allel to the support arm -1-.
– Tighten bolts for engine assembly mounting and engine brack‐
et.
– Remove support bracket - 10 - 222 A- .
– Remove bracket - T10339- and install tensioning device for
poly V-belt.
– Install poly V-belt.
– Reconnect fuel and breather lines; ensure that plug-in con‐
nectors are firmly seated.
– Install coolant expansion tank.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
AG. Volkswagen AG d
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lksw
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– Re-insert fuse for fuel pump control unit - J538- into
tho fuse hold‐ or
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– Install air filter.

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Specified torques
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♦ ⇒ “2.1 Assembly overview - toothed belt”, page 54 wit

, is n
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♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 17
hole
spec
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Prote AG.

Scirocco 2015 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 64
⇒ “3.2 Removing and installing camshaft”, page 65
⇒ “3.3 Removing and installing camshaft oil seal”, page 68
⇒ “3.4 Removing and installing camshaft adjuster”, page 71
⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”,
page 75
⇒ “3.6 Removing and installing valve stem seals”, page 77
3.1 Assembly overview - valve gear
1 - Bolt
❑ 50 Nm +180°
2 - Camshaft sprocket
3 - Seal
4 - Cylinder head AG. Volkswagen AG d
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⇒ page 45 ris
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5 - Valve guide ss au ra
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❑ Checking ⇒ page 82
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6 - Valve stem seal

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7 - Valve springs
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8 - Upper valve spring plate

spec
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9 - Valve cotter
10 - Hydraulic compensation
element
rrectne
❑ Do not interchange
s
❑ Oil contact surface

s o
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11 - Woodruff key
inform
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❑ Check for firm seating

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12 - Exhaust camshaft
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❑ Check radial clearance

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with Plastigage (roller

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❑ With integrated camshaft bearings. by c lksw
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❑ Clean sealing surface; reworking not permitted.
❑ Remove sealant residue.

Scirocco 2015 ➤
14 - Bolt
❑ 8 Nm +90°
15 - Camshaft adjuster
16 - Bolt
❑ Use counterhold - 3036- to loosen and tighten.
❑ 20 Nm +45°
17 - Inlet camshaft
❑ Check radial clearance with Plastigage, wear limit: 0.1 mm
❑ Runout: max. 0.035Vmm
olkswa AG. gen AG
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18 - Chain tensioner
Vol
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❑ Secure
rised
with locking pin - T10115- before removing.
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❑ Check for wear
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20 - Bolt ab
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❑ 10 Nm wit
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21 - Bolt
spec
es, in part or in w
❑ 10 Nm
t to the co

23 - Outlet valve
rrectness of i
❑ Do not rework. Only lapping in is permitted.

l purpos
❑ Valve dimensions ⇒ page 82

❑ Checking valve guides ⇒ page 82
nform
ercia
24 - Inlet valve
m
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io
❑ Do not rework. Only lapping in is permitted.

n
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or
❑ Valve dimensions ⇒ page 82

his
ate
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❑ Checking valve guides ⇒ page 82

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25 - Cap
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3.2 Removing and installing camshaft

3. Valve gear 65
olkswagen AG
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♦ Two-arm puller - T40001- ss
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Prote AG.
Removing
Note
♦ Never rework the sealing surfaces on the bottom of the re‐

taining frame and top of the cylinder head.
♦ The camshaft bearings are integrated into the cylinder head
and the retaining frame. The toothed belt must be relieved of
tension before the retaining frame is removed.
♦ Renew camshaft oil seal and sealing cap if retaining frame has
been unfastened.
– Removing camshaft adjuster ⇒ page 71 .

– Loosen securing bolt for camshaft sprocket and unscrew ap‐
prox. 10 mm.

Scirocco 2015 ➤
– Pull off camshaft pulley using puller - T40001- , hook -

T40001/6- and hook - T40001/7- .
The puller - T40001- is supported by the securing bolt -arrow-.
– Remove securing bolt and camshaft pulley.
– Remove rear toothed belt guard from cylinder head.
– Evenly loosen retaining frame bolts from outside to inside and
remove retaining frame.
– Carefully lift out camshafts from above and place down on a
clean surface.
– Remove old sealant from retaining frame groove and from

sealing surfaces.
olksw
– Never allow dirt or sealant
swa
residue
gen AG. V toagenter
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Install in reverse
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♦ Sealing surfaces must be free of oil and grease.
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♦ The pistons cannot be positioned at TDC.

h re
hole
♦ Ensure that all roller rocker fingers are properly seated on spec
es, in part or in w
valve stem ends.

t to the co
♦ Never rotate the camshaft when the pistons are at TDC. This
could otherwise result in damage to valves and pistons.
rrectness of i
♦ Ensure proper seating of the parallel key.

l purpos
– Oil running surfaces of both camshafts.

nform
ercia
– Carefully place camshafts into camshaft bearings of cylinder

m
a
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head. Cams -A- of cylinder 4 must face each other.

on in
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Prote AG.
3. Valve gear 67
Scirocco 2015 ➤
– Apply an even, slightly raised bead of sealant with sealant - D

154 103 A1- into clean retaining frame groove.
Note
♦ Do not apply sealant too thickly. If necessary, remove excess

sealant with a lint-free cloth.
♦ The retaining frame must be positioned and bolted on without
interruption because the sealant begins to harden immediately
when the sealing surfaces come into contact with each other.
– Place retaining frame onto cylinder head.
– Tighten new bolts gently, from inside outwards.

AG. Volkswagen AG d
– Finally, tighten bolts in the sequence shown. lksw
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– Drive sealing cap ⇒ Item 25 (page 65) in approx. 1…2 risemm
d ara
nte
deep using thrust piece - 3334- . utho eo
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– Install camshaft oil seal ⇒ page 68 . s
ce
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un
pt
– Install rear part of toothed-belt guard.
an
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– Insert Woodruff key in camshaft.
pe
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wit
– Install camshaft sprocket.
, is n
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hole
– Installing toothed belt.
spec
es, in part or in w
– Install camshaft adjuster.
t to the co
– Install cylinder head cover.
rrectness of i
Specified torques
l purpos
♦ ⇒ “3.1 Assembly overview - valve gear”, page 64
3.3 Removing and installing camshaft oil seal
nform
mercia
a
com
tion in
r
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thi
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t.
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by
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Prote AG.

Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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un
pt
an
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ab
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♦ Seal puller - 2085-

♦ Adapter - 2085/2-
♦ Two-arm puller - T40001-
♦ Thrust piece - T10353-
3. Valve gear 69
lkswage es n
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Scirocco 2015 ➤ tho tee
or
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4-cylinder injection engine (2.0 l sengine,
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turbocharger) Volkswagen R GmbH - Edition ac
09.2019
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pt
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Removing
an
itte
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erm
ab
ility
ot p
wit
– Loosen securing bolt for camshaft sprocket and unscrew ap‐
, is n
h re
prox. 10 mm.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– Pull off camshaft pulley using puller - T40001- , hook -
or
his
e
T40001/6- and hook - T40001/7- .

at
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The puller - T40001- is supported by the securing bolt -arrow-.
for
en
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t.
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– Remove securing bolt and camshaft pulley.
Co
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Prote AG.
– To guide seal extractor, screw adapter - 2085/2- into camshaft

to stop by hand.
– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.

3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor - 2085- , place it
in position and, exerting firm pressure, screw it into the oil seal
as far as possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
– Remove oil residues from crankshaft journal with a clean cloth.
– Tape over groove in taper of camshaft (e.g. using Sellotape).
– Carefully push oil seal onto camshaft journal.

Scirocco 2015 ➤
– Press in oil seal to stop using fitting sleeve - T10071- , thrust

piece - T10353- and a washer -arrow-, use bolt - T10071/4-
for this. olks
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Note
s au ra
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The thrust piece - T10353- is required for the length compensa‐

un
pt
an
d
tion of the bolt - T10071/4- . Washers can also be used.

itte
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ab
pe
ility
– Insert Woodruff key in camshaft.
ot
wit
, is n
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– Fit camshaft sprocket.
hole
spec
es, in part or in w
t to the co
Note
♦ Never rotate the camshaft when the pistons are at TDC. This
rrectness of i
could otherwise result in damage to valves and pistons.
l purpos
♦ Ensure proper seating of the parallel key.
nform
ercia
Specified torques
m
a
com
tion in
r
te o

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s
iva
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3.4 Removing and installing camshaft adjuster

fo
en
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Cop py
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rig ht
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by lksw
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Prote AG.
3. Valve gear 71
Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt

an
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♦ Camshaft clamp - T10252-

pe
ility
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wit
♦ Pin - T10115-
, is n
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hole
♦ Pin wrench - T10020-

spec
es, in part or in w

t to the co
Removing
rrectness of i
– Remove high-pressure pump ⇒ page 175 .

l purpos
– Remove cylinder head cover ⇒ page 50 .

nform
mercia
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com
tion in
r
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thi
s
iva
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cum
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤

– Release coolant pipe from heat shield.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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aut ra
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pt
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– Release cable retainer -arrow-.
itte
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ab
– Remove vacuum pump (if fitted).
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
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om
– Remove cover from camshaft adjuster.
ion
c
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or
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ate
do
priv
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for
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
– Align marking on camshaft pulley with marking on toothed belt

guard; recesses -arrows- now point vertically to each other.
3. Valve gear 73
Scirocco 2015 ➤
AG. Volkswagen AG d
– Fit camshaft clamp - T10252- as shown and secure -arrows-. lkswagen oes
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– Loosen securing bolt of camshaft adjuster with specialrised b ara
nte
wrench, long reach - T40080- . ut
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spec
es, in part or in w
t to the co
– Compress chain tensioner -arrow A- and secure with locking
pin - T10115- -arrow B-.
rrectness of i
– Unscrew securing bolt of camshaft adjuster and remove with
l purpos
chain.
Installing
nform
ercia

m
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tion in
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• The camshafts are located with the camshaft clamp - gh ht
yri by
T10252- . cop Vo
by lksw
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Prote AG.
– Place chain on camshaft adjuster.
– Hold camshaft adjuster in front of exhaust camshaft so that

notch -A- and pin -B- align.

Scirocco 2015 ➤
– Lay chain over intake camshaft sprocket starting at top

-arrow- without changing its position.
– Turn intake camshaft slowly in -direction of arrow A- using pin

wrench - T10020- until the camshaft adjuster fits onto the
camshaft.
Note
If pin does not fit into notch, remove chain and fit it again.
AG. Volkswagen AG d
agen oes
lksw not
– Tighten camshaft
d by
Vo
adjuster bolt. To do this, use gu special wrench,
ara
long reach
orise - T40080- . nte
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– Remove locking pin - T10115- -arrow B-.

d
itte
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Specified torques
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
3.5 Removing and installing camshaft control valve 1 - N205-

mer
atio
om
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c
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or
n thi
te
sd
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pr
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Cop py
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Prote AG.
3. Valve gear 75
Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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nl
pt
du
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♦ TORX bit set - V.A.G 1766-
ility
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wit
♦ Ratchet insert 1/4" - VAS 6234-
, is n
h re
hole
♦ Pliers for spring-type clips - VAS 5024 A- spec

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

rrectness of i

l purpos
– Release wiring harness -2- from retainer.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤

– Pull camshaft control valve 1 - N205- out of housing.
Installing
Note
♦ The inlet camshaft control valve 1 - N205- and housing must

be free of dirt and soiling.
♦ Do not unpack the camshaft control valve 1 - N205- until im‐
mediately prior to installation.
Caution
♦ Ensure the inlet camshaft control valve 1 - N205- is pro‐

tected from knocks and impacts.
– Coat oil seal with engine oil.

Specified torques
3.6 Removing and installing valve stem

seals
(With cylinder head installed)
lkswage es n
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tho
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a ac
ss
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pt
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itte
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ab
ility
ot p
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
by
77
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Prote AG.
3. Valve gear
Scirocco 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
♦ Spark plug socket - 3122 B- t to the co
♦ Valve stem seal puller - 3364-

rrectness of i
♦ Valve stem seal fitting tool - 3365-

l purpos
♦ Adapter - T40012-
nf
ercia
♦ Dismantling and assembling device for valve cotters - VAS

rm
m
atio
5161-
om
n in
c
♦ Guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B-
or
thi
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sd
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Removing
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o
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rp
cu
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m
f
– Remove camshafts ⇒ page 65 .

en
ng
t.
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op
– Remove roller rocker fingers, and place them on a clean sur‐
C py
t. rig
gh
face making sure that roller rocker fingers are not inter‐
ht
pyri by
Vo
o
changed. by c lksw
cted agen
Prote AG.
– Remove spark plugs using spark plug socket and extension -
3122 B- .

Scirocco 2015 ➤
– Secure guide plate for 2.0 l and 3.0 l FSI engine - VAS
5161/19B- with knurled screws - VAS 5161/12- to cylinder
head as shown.
– Set piston of respective cylinder to “bottom dead centre”.
– Screw adapter - T40012- into spark plug thread and connect

compressed air with pressure of at least 6 bar.
– Strike tight valve cotters with drift - VAS 5161/3- and a plastic
hammer.
– Screw retainer - VAS 5161/6- with guide fork - VAS 5161/5-

into guide plate for 2.0 l and 3.0 l FSI engine - VAS 5161/19B- .
– Insert assembly cartridge - VAS 5161/8- into guide plate for
2.0 l and 3.0 l FSI engine - VAS 5161/19B- .
– Attach pressure fork - VAS 5161/2- to retainer - VAS 5161/6- .
AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
ed ran
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th or
au ac
ss
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nl
pt
du
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itte
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erm
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ility
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wit
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Note
h re
hole
spec
On the exhaust side, the pressure fork - VAS 5161/2- must be

es, in part or in w
t to the co
attached as shown.
– Press installation cartridge - VAS 5161/8- down and turn

rrectness of i
knurled screw of installation cartridge - VAS 5161/8- to right

until tips engage in valve cotters.
l purpos
– Move knurled screw back and forth gently, as a result of which

nf
valve cotters are pressed apart and taken up in installation

ercia
cartridge.
rm
m
atio
m
– Release pressure fork - VAS 5161/2- .

o
n in
or c
thi
– Remove installation cartridge - VAS 5161/8- .

te
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pyri by
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co lksw
by
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Prote AG.
3. Valve gear 79
Scirocco 2015 ➤
– Pull off valve stem seals using valve stem seal puller - 3364- .
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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ce
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un
pt
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d
itte
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If valve stem seal puller - 3364- cannot be used on account of
restricted space, knock out pin -arrow- with a punch and re‐
rrectness of i
move the impact extractor attachment.
l purpos
nform
mercia
a
com
tion in
r
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thi
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t.
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op py
– Place lower part of valve stem seal puller - 3364- onto valve t. C rig
gh ht
stem seal. yri
p by
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cted
– Insert punch -1- into bore in lower part of puller.
agen
Prote AG.
– Place installation lever on installation device and pull out valve

stem seal -arrow-.
Installing
– To prevent damage to new valve stem seals -B-, attach plastic

sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem seal fitting tool - 3365- and push carefully onto valve
guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Install removal and installation device for valve cotters - VAS
5161- as shown.

Scirocco 2015 ➤
Inlet side
Exhaust side
AG. Volkswagen AG d
agen oes
olksw not
Note ed by
V gu
ara
ris nte
ho eo
ut
♦ If the valve cotters have been removed from the sinstallation
s a ra
c
cartridge, they must first be inserted into the insertion device
ce
e
nl
- VAS 5161/18- .
pt
du
an
itte
y li
♦ Press assembly cartridge - VAS 5161/8- onto inserting device
erm
ab
from above and capture valve cotters.
ility
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wit
, is n
h re
– Press installation cartridge - VAS 5161/8- down with pressure
hole
spec
fork - VAS 5161/2- , and pull installation cartridge knurled
es, in part or in w
screw back and forth whilst pulling upwards.
t to the co
– Relieve pressure fork - VAS 5161/2- whilst pulling on knurled
screw.
rrectness of i
– Remove removal and installation device for valve cotters -
l purpos
VAS 5161- .
– Install camshafts ⇒ page 65 .
nf
ercia
orm
m
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n in
or c
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Prote AG.
3. Valve gear 81
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ris nte
Scirocco 2015 ➤ ut
ho eo
ra
a
4-cylinder injection engine (2.0
s l engine, turbocharger) Volkswagen R GmbH - Edition
s c 09.2019
ce
e
nl
pt
du
an
itte
4 Inlet and exhaust valves
y li
erm
ab
ility
ot p
⇒ “4.1 Valve dimensions”, page 82
wit
, is n
h re
⇒ “4.2 Checking valve guides”, page 82
hole
spec
es, in part or in w
4.1 Valve dimensions
t to the co
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
rrectness of i
Dimension Inlet valve Outlet valve
l purpos
∅a mm 33.75 … 33.95 27.90 … 28.10
nform
ercia
∅b mm 5.98 5.95
c mm 103.97 101.87
m
at
om
io
α ∠° 45 45
n
c
in t
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4.2 Checking valve guides
ht. rig
rig ht
py by
co Vo
by lksw
Special tools and workshop equipment required cted agen
Prote AG.
♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-

Scirocco 2015 ➤
Test sequence
– Insert new valve in guide. End of valve stem must be at same
height as guide. On account of differing stem
AG. Vodiameters,
lkswagen AG only
agen d
use inlet valve in inlet guide and Voexhaust
lksw valve in exhaustoes not g
guide. ed
by ua
ran
is tee
or
– Determine rock. Wearalimit:
ut
h
0.8 mm or
ac
ss
If the amount of sideways play is exceeded:
ce
le
un
pt
an
d
– Renew cylinder head.

itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
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thi
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cum
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Inlet and exhaust valves 83

Scirocco 2015 ➤
17 – Lubrication
AG. Volkswagen AG d
agen oes
1 d by Volksw
Sump, oil pump not
gu
ara
rise nte
⇒ “1.1 Assembly overview
utho - sump/oil pump”, page 84 eo
ra
s a c
⇒ “1.2 Removing and installing oil sump”, page 86
s
ce
le
un
pt
⇒ “1.3 Engine oil:”, page 88
an
d
itte
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ab
1.1 Assembly overview - sump/oil pump
ility
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wit
is n
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Note
spec
t to the co
♦ If large quantities of metal chips and abraded material are found during engine repair, this may indicate that
the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following
work must be carried out following the repair:
rrectne
♦ Thoroughly clean oil channels.
ss
♦ Renew oil spray jets.
o
cial p
f in
♦ Renew engine oil cooler.
form
mer
atio
♦ Renewing oil filter.
om
n
c
i
♦ The oil level must remain below the max. mark - danger of damage to catalytic converter!
or
n thi
te
sd
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cum
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t.
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Cop py
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pyri by
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by
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Prote AG.
84 Rep. gr.17 - Lubrication

Scirocco 2015 ➤
1 - Bolt
❑ 15 Nm
2 - Oil dipstick
❑ Markings ⇒ page 89 .
❑ The oil level must not be
above the max. mark
3 - Piston fitting tool
4 - Guide tube
5 - Adapter
6 - Oil pump with balance shaft
module
❑ With 12 bar pressure re‐
lief valve
⇒ page 100 gen AG
. Volkswagen AG
d wa oes
olks not
7 - Bolt db
yV gu
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❑ Renew thoafter removal
r eo
au ra
❑ Note ss different bolt c
lengths ⇒ page 100 ce
le
un
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an
d
❑ 15 Nm +90°
itte
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rm
ab
8 - Bolt
pe
ility
ot
wit
, is n
h re
quence ⇒ page 86 .
hole
spec
❑ 15 Nm
es, in part or in w
t to the co
9 - Bolt
❑ To secure charge air
pipe.
rrectness of i
❑ 8 Nm
l purpos
10 - Oil pan
❑ Clean sealing surface
nform
ercia
before fitting.
m

com
tion in
r
te o
11 - Bolt
thi
s
iva
do
❑ 15 Nm
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12 - Oil drain plug

en
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t.
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op
❑ Renew after removal C py
t. rig
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❑ With captive seal yri
p by
co Vo
by lksw
❑ 30 Nm cted agen
Prote AG.
13 - Sprocket
14 - Bolt
❑ 10 Nm
15 - Cap
16 - Oil level and oil temperature sender - G266-
17 - Seal
❑ Lubricate before installing.
18 - Bolt
1. Sump, oil pump 85

Scirocco 2015 ➤
❑ 20 Nm +90°
19 - Chain guard
20 - Chain
21 - Sealing flange
❑ Must seat on dowel sleeves. AG. Volkswagen AG d
agen oes
❑ Removing and installing ⇒ page
olksw
23 not
yV gu b ara
ed nte
oris e
th or
au ac
ss
1.2 Removing and installing oil sump
ce
le
un
pt
an
d

itte
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erm
ab
♦ T-bar and socket, 10 mm - 3185-
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om

n
c
i
or
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
♦ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

♦ Scraper
Removing
insulation .
– Drain engine oil.
Note
Please observe disposal instructions!

Scirocco 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
thi
te
sd
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o
pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Loosen sump bolts on flywheel end using T-bar and socket,
10 mm - 3185- and remove with special wrench, long reach -
T10058- .
– Remove bolts -1 … 20-.
– Remove sump.
– Remove sealant residues from cylinder block with a flat scra‐
per.

Scirocco 2015 ➤
– Remove remaining sealant from sump e.g. with rotating plastic

brush or similar.
Installing
Note

♦ The sump must be installed immediately and tightened after
applying silicone sealing compound.

3 mm).
– Apply silicone sealant to clean sealing surface of sump as
shown. Sealant bead must be:
♦ 2…3 mm thick
AG. Volkswagen AG d
agen oes
♦ Run bead along inner side of bolt holes -arrows-.
yV
olks
w not
gu
b ara
ed nte
oris eo
th
Note au ra
c
ss
ce
le
un
pt
♦ Do not make the sealant bead thicker. Otherwise, excess
an
d
itte
sealant will make its way into the sump and block the strainer
y li
rm
ab
or sieve in the suction line of the oil pump.
pe
ility
ot
wit
♦ If gearbox is removed, sump must align smoothly with cylinder
, is n
h re
block.
hole
spec
♦ If gearbox is installed, sump must rest against gearbox.
es, in part or in w
t to the co
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
rrectness of i
– Position oil sump immediately and tighten bolts as follows:

l purpos
1 - Slightly tighten all sump/cylinder block bolts diagonally.

nform
ercia
2 - Tighten sump/gearbox bolts slightly.

m
3 - Tighten all sump/cylinder block bolts slightly and diagonally.

com
tion in
4 - Tighten sump/gearbox bolts.

r
te o
thi
s
iva
do
5 - Diagonally tighten all sump/cylinder block bolts.

r
rp
cum
fo
Specified torques
en
ng
t.
yi Co
op
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 84
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Sump/gearbox bolt 40 Nm
1.3 Engine oil:

Oil capacities:
With oil filter 4.6 l
without oil filter 4.1 l.
Engine oil specifications ⇒ Maintenance ; Booklet ; Service ta‐
bles .

Scirocco 2015 ➤
Change engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or

extract; renew oil filter and replenish engine oil .
Markings on oil dipstick:
1 - Max. mark
2 - Min. mark
a - Oil level in max. mark area: Do not replenish engine oil!
b - Oil level in middle range: can be topped up with engine oil.
c - Oil level in min. mark area: Replenish with approx. 0.5 l engine
oil!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”,
page 90
⇒ “2.2 Removing and installing oil pressure switch F1 ”,
page 92
⇒ “2.3 Removing and installing oil filter housing”, page 93
⇒ “2.4 Checking oil pressure and oil pressure switch”,
page 94
2.1 Assembly overview - oil filter housing, oil pressure switch
Note
♦ If large quantities of metal chips and abraded material are found during engine repair, this may indicate that
the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following
work must be carried out following the repair:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets.
♦ Renew engine oil cooler.
♦ Renewing oil filter.
♦ The oil level must remain below the max. mark - danger of damage to catalytic converter!
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
1 - Tube
❑ For crankcase ventila‐
tion.
2 - Oil pressure switch - F1-
❑ 1.4 bar, black
❑ With earth wire for oil
pressure switch (only
with single pin oil pres‐
sure switch).
❑ Checking oil pressure gen AG
. Volkswagen AG
does
switch ⇒ page 94 . Volkswa not
y gu
ris
ed b ara
nte
⇒ page 92 uth o eo
ra
a
❑ 21 Nm ss c
ce
le
un
pt
3 - Bolt
an
d
itte
y li
❑ With earth wire for oil
erm
ab
pressure switch (only
ility
ot p
with single pin oil pres‐
wit
is n
sure switch).
h re
ole,
spec
❑ 15 Nm
t to the co
4 - Bracket
5 - Bolt
rrectne
❑ 15 Nm
6 - Engine oil cooler
ss o
❑ Ensure clearance to ad‐
cial p
f i
jacent components nform
mer
❑ Connection diagram for

atio
m
coolant hoses
o
n
c
⇒ page 105
i
or
n thi
te
sd
a
7 - Seal
iv
o
pr
cum

r
fo
en
ng
t.
yi Co
8 - Oil filter housing t. Cop py
rig
❑ Fully drain using oil drain adapter - T40057-
gh ht
pyri by
Vo
co
❑ Remove and install with oil filter tool - 3417- .
by lksw
cted agen
Prote AG.
❑ 25 Nm
9 - Dust cap
10 - Seal
❑ Coat with oil before inserting
❑ Service tag at top
11 - Oil filter element
❑ Before removing, fully drain oil filter housing ⇒ Maintenance ; Booklet ; Engine oil: draining or extracting;
Renewing oil filter and replenishing engine oil
❑ Renew ⇒ Maintenance ; Booklet ; Engine oil: draining or extracting; renewing oil filter and replenishing
engine oil
12 - Bolt
❑ 15 Nm +90°
13 - Baffle plate
❑ Fitting position ⇒ page 92
2. Oil filter, oil pressure switch 91

Scirocco 2015 ➤
14 - Seal
15 - Oil filter bracket
❑ With pressure relief valve, approx. 4 bar
Installation position of baffle plate
2.2 Removing and installing oil pressure

switch - F1-
. Volkswagen AG
gen AG does
Special tools and workshopVequipment
olks
wa required not
by gu
d ara
♦ Jointed wrench 24ormmise - T40175- nte
eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

nform
ercia
insulation .
m
at
om

ion
c
in t
or
– Remove charge air hose.

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Scirocco 2015 ➤
– Remove connector -1- from retainer.

– Pull connector -arrow- off oil pressure switch.
Vehicles with a 1-pin oil pressure switch:
AG. Volkswagen AG d
agen oes
ksw not
– Unscrew bolt -B- for earth lineb(ignore
yV
ol
arrows). gu
ara
d
ise nte
All vehicles: thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew oil pressure switch with 24 mm articulated wrench -
rrectness of i
T40175-
l purpos
Installing
nf
ercia
Specified torques orm

m
atio
om
n in
♦ ⇒ “2.1 Assembly overview - oil filter housing, oil pressure

or c
switch”, page 90
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
t. rig
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yri by
2.3 Removing and installing oil filter housing
cop Vo
by lksw
cted agen
Prote AG.
Removing
– Remove coolant pipes ⇒ page 120 .
– Unscrew bolts -A and B-.
– Remove engine oil cooler.

Scirocco 2015 ➤
– Release electrical connector -A-.gen AG. Volkswagen AG d

wa oes
olks not
– If fitted, unscrew bolt -B-d bfor
y V earth wire. gu
ara
e nte
ris
ut
ho eo
ra
a c
ss
– Remove oil filter housing.
ce
le
un
pt
an
Installing
d
itte
y li
rm
ab
pe
ility
ot
wit
Specified torques
, is n
h re
hole
♦ ⇒ “2.1 Assembly overview - oil filter housing, oil pressure
spec
switch”, page 90
es, in part or in w
t to the co
2.4 Checking oil pressure and oil pressure
rrectness of i
switch
l purpos
⇒ “2.4.1 Checking oil pressure and oil pressure switch (single pin
oil pressure switch)”, page 94
nform
ercia
⇒ “2.4.2 Checking oil pressure and oil pressure switch (2-pin oil
pressure switch)”, page 95
m
a
com
tion in
2.4.1 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
equipment required
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527 B-
♦ Adapter set - V.A.G 1594C-
• Engine oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Procedure
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- ; the LED must remain unlit.
– If the LED lights up, renew 1.4 bar oil pressure switch - F1- .
If LED does not light up:
– Start engine and increase rpm; at pressure of 1.2 to 1.6 bar,
LED must light up. Otherwise, renew oil pressure switch.
AG. Volkswagen
– Increase engine speed further. wage At 2000 rpm anddan
n AG o
es noil tem‐
olks
perature of 80°C, thed byoil pressure should be between t2.7
V o g
ua to
4.5 bar. or
ise ran
te
h eo
ut ra
At higher engine
ss speeds, the oil pressure must not exceed 7.0
a c
bar.
ce
e
nl
pt
du
an

itte
y li
erm
ab
– Check strainer in oil intake pipe for soiling.

ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
rrectness of i
If no fault is found:
l purpos
– Renew oil pump ⇒ page 100 .

If the specification is exceeded:
nf
ercia
orm
– Check oil channels.

m
atio
om
n in
– If necessary, replace oil filter bracket with pressure relief valve.

or c
thi
te
sd
iva
2.4.2 Checking oil pressure and oil pressure

o
r
rp
cu
o
m
f
switch (2-pin oil pressure switch)

en
ng
t.
yi Co
Cop py
.
ht rig
rig ht
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co Vo
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Prote AG.

Scirocco 2015 ➤
♦ Oil pressure tester - V.A.G 1342- AG. Volkswagen AG d

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♦ Hand multimeter - V.A.G 1526 E-
rrectness of i
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♦ Test instrument adapter/DSO (2-pin) - VAS 5256- gh ht
pyri by
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• Engine oil level OK.

• Engine oil temperature at least 80°C (radiator fan must have
run once)

Scirocco 2015 ➤
Procedure
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect test instrument/DSO adapter (2-pin) - VAS 5256- to
oil pressure switch
– Connect Multimeter - V.A.G 1526E- to test instrument/DSO
adapter (2-pin) - VAS 5256- and check for continuity.
• Oil pressure switch must be open at a pressure below 1.2 bar.
– Start engine and increase rpm; oil pressure switch must close
at pressure of 1.2…1.6 bar. Otherwise renew oil pressure
switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80°C, the oil pressure should be between 2.7 to
4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
– Check strainer in oil intake pipe for soiling.
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found: agen

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– Fit new oil pump ed b with
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If the specification
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– Check oil channels.
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– If necessary, replace oil filter bracket with pressure relief valve.

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Scirocco 2015 ➤
AG. Volkswagen AG d
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⇒ “3.1 Assembly overview - oil circuit”, pagea98
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3.1 Assembly overview - oil circuit
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1 - Seal
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2 - Banjo bolt
spec
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❑ 30 Nm
t to the co
3 - Oil supply line
4 - Turbocharger
rrectness of i
l purpos
⇒ page 129
5 - Bolt
nf
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❑ 9 Nm
rm
m
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6 - Banjo bolt
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❑ 30 Nm
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8 - Banjo bolt
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9 - Seal
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10 - Coolant supply line
11 - Bolt
❑ 23 Nm
12 - Banjo bolt
❑ 35 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
15 - Seal
16 - Oil return line
17 - Bolts
❑ 9 Nm
18 - Seal

Scirocco 2015 ➤
4 Balancer shaft module

⇒ “4.1 Assembly overview - balancer shaft module”, page 99
⇒ “4.2 Removing and installing balance shaft module”,
page 100
4.1 Assembly overview - balancer shaft module
1 - Chain guard
2 - Chain
❑ Before removing, mark
running direction (instal‐ wage
es n
s
lation position) with yV
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paint. ir se
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tee
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3 - Dowel sleeves au ac
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4 - Adapter
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5 - Oil pump with balance shaft
y li
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module
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❑ Before installing, ensure
wit
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that both dowel sleeves
h re
hole
for centring are instal‐
spec
led.
es, in part or in w
t to the co
⇒ page 100
rrectness of i
6 - Bolt
❑ 9 Nm
l purpos
7 - Cover
nf
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❑ Prevents engine oil from
or
foaming
m
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8 - Bolt
n in
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❑ 40 Nm
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9 - Bolt cu
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❑ 8 Nm
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10 - Oil intake tube
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❑ Clean strainer if soiled
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11 - O-ring
12 - Bolt
❑ Note different bolt lengths
❑ 15 Nm +90°
13 - Outer rotor
❑ Check running surfaces for scoring.
❑ Marking must be visible.
14 - Inner rotor
❑ Check running surfaces for scoring.
4. Balancer shaft module 99

AG. Volkswagen AG d
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Scirocco 2015 aut ➤
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4-cylinder injection
s engine (2.0 l engine, turbocharger) Volkswagen R GmbH - Edition 09.2019
ce
le
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15 - Oil pump cover
itte
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16 - Sprocket
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17 - Bolt
h re
ole,
spec
❑ 20 Nm +90°
t to the co
18 - Chain tensioner with tensioning rail
❑ Preload when installing ⇒ page 100 .
rrectne
19 - Bolt
s
❑ 15 Nm
s o
cial p
f inform
mer
atio
4.2 Removing and installing balance shaft
om
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module
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♦ Pin - T10027-
t.
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Prote AG.
Removing
Note
Oil pump and balance shaft module are combined in one unit.
– Remove sump ⇒ page 86 .

– Using a small screwdriver, release locking lugs through open‐
ings -arrows-.
– Pull off chain guard.

AG. Volkswagen AG d
agen oes Scirocco 2015 ➤
olksw not
d by
V
Volkswagen R GmbH - Edition gu
ara 09.2019
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– Set engine to TDC No. 1 cylinder. aut ra
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ility
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Note
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Check that there is a mark on balance shaft sprocket which aligns
m
atio
m
with locking hole -arrow-. If there is no mark, mark position using

o
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c
a waterproof pen. The mark is required for reinstalling.

or
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Prote AG.
– Loosen oil pump sprocket bolt; counterhold on centre bolt of
vibration damper to do so.
Caution
Do not loosen the balance shaft drive sprocket!
– Relieve tension on chain guide using a screwdriver -arrow-

and lock using a 3 mm Allen key -1-.

Scirocco 2015 ➤
– Remove oil pump sprocket and detach chain from balance

shaft gear assembly.

– Remove baffle plate.
– Unscrew balance shaft module bolts working from outside in‐

wards.
– Remove balance shaft module.
Installing
G. Volkswagen nA AG do
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• Chain tensioner must be pre-tensioned.
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Preloading chain tensioner thoris tee
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– Preload piston by hand -arrow-.

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Prote AG.

Scirocco 2015 ➤
– Press chain guide -in direction of arrow- and lock in place using
3 mm hexagon socket head key -1-.
Continuation
– Fit intermediate plate onto dowel sleeves of balance shaft

module -arrows-.
– Install oil pump with balance shaft module and intermediate

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– Tighten bolts diagonally rworking
ise
d from inside outwards. ara
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Note
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Note different bolt lengths ⇒ page 104

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– Set engine to TDC No. 1 cylinder.

rrectness of i
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Cop py
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by
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Prote AG.

Scirocco 2015 ➤
– Align marking on balance shaft sprocket -arrow- with fixing

hole.
AG. Volkswagen AG d
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– In this position, lock sprocket using locking pin - T10027- by V .
ol
gu
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Place chain on balance shaft sprocket. rise
d
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– Install oil pump sprocket and tighten bolt by hand.
ss au ra
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Note
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The oil pump sprocket can only be installed correctly in one po‐
wit
is n
sition. For installation, only the oil pump may be turned.
h re
ole,
spec
t to the co
– Remove locking pin - T10027- and Allen key -1-.
rrectne
– Secure oil pump sprocket; counterhold on centre bolt of vibra‐
s
tion damper to do so.
s o
cial p
f
– Install sump ⇒ page 86 .
inform
mer
atio
om
n
c
i
or
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te
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t.
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Bolt allocation for balance shaft module cop Vo
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Prote
A - Hexagon head collar bolt M7 × 40
AG.
B - Hexagon head collar bolt M7 × 70

C - Hexagon head collar bolt M7 × 90
D - Hexagon head collar bolt M7 × 55
E - Plug with O-ring
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 84
♦ ⇒ “4.1 Assembly overview - balancer shaft module”, page 99

Scirocco 2015 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 105
⇒ “1.2 Draining and adding coolant”, page 107
⇒ “1.3 Checking cooling system for leaks”, page 112
1.1 Connection diagram - coolant hoses
1 - Radiator/cooler
⇒ page 124
❑ If renewed, refill system
with fresh coolant.
2 - Coolant circulation pump -
V50-
❑ The flow of the coolant
in the run-on phase is
opposite to the flow
shown.
❑ The function can be
checked using final con‐
trol diagnosis ⇒ Vehicle
diagnostic tester.
3 - Bypass thermostat
❑ Depending on equip‐
ment
4 - Thermostat housing
❑ With thermostat AG. Volkswagen AG d
agen
❑ Checking thermostat Volksw
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⇒ Vehicle diagnostic ed by ara
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tester horis
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5 - Coolant pump ss c
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nl

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⇒ page 115
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6 - Cylinder head/cylinder
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block
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❑ If renewed, refill system

hole
spec
with fresh coolant.

es, in part or in w
t to the co
7 - Turbocharger
⇒ page 129
rrectness of i
8 - Expansion tank
l purpos
❑ When renewing expansion tank and during service operations, ensure that 2 silicate cartridges ⇒ Elec‐
tronic Parts Catalogue are always in expansion tank. Do not remove the silicate cartridges.
nf
ercia
❑ With cap
rm
m
atio
❑ Check cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling
om
system tester - V.A.G 1274/8-

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9 - Heat exchanger for heater

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❑ If renewed, refill system with fresh coolant.

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1. Cooling system/coolant
AG.
Scirocco 2015 ➤
10 - Hose
❑ Only for automatic gearbox.
11 - Gear oil cooler
12 - Bypass thermostat
13 - Coolant connection
14 - Engine oil cooler
15 - Intake manifold
16 - Hose
❑ Only for auxiliary radiator
17 - Auxiliary radiator
❑ Optional equipment
18 - Hose
❑ Only for auxiliary radiator
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mer
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c
i
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by
cted agen
Prote AG.
106 Rep. gr.19 - Cooling

AG. Volkswagen AG d
lksw
agen oes
not Scirocco 2015 ➤
o
4-cylinder injection engine (2.0 l engine, d by turbocharger) Volkswagen R GmbH
V gu
ara - Edition 09.2019
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1.2 Draining and adding coolant au ra
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itte
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equipment required
ility
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mer
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Prote AG.
♦ Refractometer - T10007 A-
♦ Drip tray - V.A.G 1306-
♦ Installation tool for spring-type clips - VAS 5024 A-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter - V.A.G 1274/8-
Draining
WARNING
The cooling system is under pressure when the engine is hot!

Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
1. Cooling system/coolant 107

Scirocco 2015 ➤
– Open filler cap on coolant expansion tank.

insulation .
– Release quick-release coupling -arrow-.
– Pull coolant hose off radiator.
– Loosen clamp -arrow-.

– Place drip tray - V.A.G 1306- underneath.
– Pull off coolant hose, and allow coolant to drain out.
Filling
Caution n AG. Volkswagen AG do

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Use only distilled water for mixing
oris coolant additives. The use tee
of distilled water ensures soptimum
au
th
protection against corro‐ or
ac
sion. s
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nl
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du
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itte
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erm
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ility
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wit
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hole
spec
es, in part or in w
t to the co
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orm
m
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Cop py
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by
cted agen
Prote AG.

Scirocco 2015 ➤
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and
swa
gcor‐
en AG. V
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does
rosion damage as well as scaling. Such additivesbyalso Vol raise
k not
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the boiling point of the coolant. For this reason,
ris
edthe cooling ara
nte
system must be filled all-year-round with coolant
ut
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♦ Because of its high boiling point, the coolant
s
improves engine
ce
e
reliability under heavy loads, particularly in countries with trop‐

nl
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♦ ONLY refractometer - T10007A- may be used for determining
ility
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current anti-freeze value.
wit
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♦ Frost protection must be guaranteed down to -25°C as a min‐
hole
spec
imum and, in countries with arctic conditions, down to approx.
es, in part or in w
-36°C. Increasing the frost protection is permissible only if cli‐
t to the co
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
rrectness of i
♦ Do not reduce the coolant concentration by adding water even
l purpos
in warmer seasons and in warmer countries. Frost protection

must be guaranteed down to at least -25°C.
nform
ercia
♦ Read off anti-freeze figures for respective replenished coolant

additives.
m
at
om
ion
c
♦ The temperature read off the refractometer - T10007A- corre‐

in t
or
sponds the »ice flocculation point«. Flakes of ice may start his
ate
forming in the coolant below this temperature.

do
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♦ Never reuse old coolant.

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♦ Use only a water/coolant additive mixture as a slip agent for
C py
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coolant hoses.
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Prote AG.
Coolant mixture ratio
• Coolant additive (40%) and water (60%) for frost protection to
-25°C
• Coolant additive (50%) and water (50%) for frost protection to
-36°C
• Coolant additive ⇒ Electronic parts catalogue

Scirocco 2015 ➤
– Fill coolant expansion tank of -VAS 6096- with 10 litres of pre-

mixed coolant in correct mixture ratio; mixture ratio
⇒ page 109 .
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Feed vent hose -1- into a small container -2-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -3- to compressed air.
• Pressure: 6 to 10 bar.
lkswage es n
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om
ion
c
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ate
do
priv
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ng
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Prote AG.

Scirocco 2015 ➤
– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– Also briefly open valve -A- (turn lever in direction of flow to do
this) so that hose on -VAS 6096- coolant reservoir fills with
coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
Volkswagen AG
• Vacuum continues to be generated in the cooling system agen by
AG. does
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the suction jet pump; the needle of gauge mustbremain
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– Close valve -B-. ss au ra
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– Pull off compressed air hose.

nl
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• The needle on the gauge should stop in the green zone. The
erm
ab
vacuum level in the cooling system is then sufficient for sub‐
ility
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sequent filling.
wit
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spec
Note
es, in part or in w
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♦ If the needle does not reach the green zone, repeat the proc‐
ess.
rrectness of i
♦ If vacuum drops, cooling system must be checked for leaks.
l purpos
– Open valve -A- slowly.
nf
ercia
• Vacuum in cooling system causes coolant to be extracted from
orm
-VAS 6096- coolant reservoir and coolant system to be filled.
m
atio
om
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c
– Remove cooling system charge unit - VAS 6096- from coolant

or
thi
expansion tank.
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– Fill coolant up to max. mark.

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– Install noise insulation ⇒ General body repairs, exterior; Rep.

t.
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op
gr. 66 ; Noise insulation; Removing and installing noise insu‐
C py
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lation .
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– On vehicles with auxiliary heater, switch on auxiliary heater for
cted agen
Prote AG.
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor. To do this, press AC
button.
• LED in button should not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap of coolant expansion tank until it engages.
– Run engine at idling speed until both large coolant hoses on
radiator are heated up.
– Switch off engine and let it cool off.
– Check coolant level.
• When the engine is cold, the coolant level must be between
“min.” and max. marking.

Scirocco 2015 ➤
• The coolant level may be at the max. marking when the engine
is warm.
1.3 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8- agen

AG. Volkswagen AG d
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Adapter for cooling system tester - V.A.G 1274/9-
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
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• Engine at operating temperature. Prote AG.
Procedure
WARNING


AG. Volkswagen AG d
agen oes
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d b ara
rise nte
Scirocco 2015 ➤
autho eo
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ce
e
nl
pt
du
an
– Open filler cap on coolant expansion tank.
itte
y li
erm
ab
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
ility
ot p
coolant expansion tank.
wit
, is n
h re
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling hole
spec
system tester - V.A.G 1274/8- .
es, in part or in w
t to the co
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Using hand pump of tester, build up a pressure of approx.
rrectness of i
1.0 bar.
l purpos
DANGER!
nform
ercia
Risk of scalding! Before the cooling system tester - V.A.G 1274

m
at
om
B- is disconnected from the connecting hose or the connector
ion
c
- V.A.G 1274 B/1- it is essential that the pressure is first re‐
in t
or
his
e
lieved. To do this, press pressure relief valve on cooling system

at
do
riv
tester - V.A.G 1274 B- until pressure gauge displays value of

p
cum
»0«.
for
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If the pressure drops:
ht
pyri by
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cted
– Find leaks and rectify.
agen
Prote AG.
Checking pressure relief valve in filler cap:
– Screw cap into adapter for cooling system tester - V.A.G

1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Connect connector - V.A.G 1274 B/1- to cooling system tester
- V.A.G 1274 B- using supplied hose.
– Operate hand pump.
• The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.

Scirocco 2015 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 114
⇒ “2.2 Assembly overview - electric coolant pump”, page 115
⇒ “2.3 Removing and installing coolant pump”, page 115
⇒ “2.4 Removing and installing thermostat”, page 116
⇒ “2.5 Removing and installing coolant temperature sender G62
”, page 117
⇒ “2.6 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 118
2.1 Assembly overview - coolant pump, thermostat
1 - Bolt
❑ 15 Nm
2 - Coolant pump
⇒ page 115
AG. Volkswagen AG d
3 - O-ring agen oes
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❑ Renew after removal d by ara
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4 - Thermostat with housing s aut ra
c
s
ce
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un
pt
⇒ page 116
an
d
itte
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5 - O-ring
rm
ab
pe
ility
ot
wit
, is n
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6 - Front coolant pipe
hole
spec
es, in part or in w
⇒ page 120
t to the co
7 - Bolt
❑ 9 Nm
rrectness of i
8 - Radiator outlet coolant tem‐
l purpos
perature sender - G83-

❑ Removing and installing nform
ercia
⇒ page 118
m
9 - O-ring
com
tion in

r
te o
thi
s
iva
do
10 - Retaining clip
r
rp
cum
fo
11 - Coolant hose
en
ng
t.
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op
❑ With mount for radiator C py
t. rig
outlet coolant tempera‐
gh ht
yri by
ture sender - G83-
op Vo
by c lksw
cted agen
Prote AG.
12 - O-ring
13 - Bolt
❑ 9 Nm

Scirocco 2015 ➤
14 - O-ring
2.2 Assembly overview - electric coolant pump

AG. Volkswagen AG d
agen oes
olksw not
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1 - Nut d b ara
rise nte
❑ 3 Nmautho eo
ra
ss c
2 - Coolant pipe
ce
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un
pt
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d
3 - Spring-type clip
itte
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rm
ab
4 - Coolant line
pe
ility
ot
wit
❑ To turbocharger
, is n
h re
hole
5 - Coolant hose
spec
es, in part or in w
6 - Bracket
t to the co
7 - Coolant hose
❑ To cooler opening
rrectness of i
8 - Coolant circulation pump -
l purpos
V50-
❑ The function can be
nform
ercia
checked using final con‐

trol diagnosis ⇒ Vehicle
m
a
com
t
diagnostic tester.
ion in
r
te o
9 - Bolt
thi
s
iva
do
❑ 5 Nm
r
rp
cum
fo
en
g
10 - Nut
n
t.
yi Co
op
❑ 5 Nm
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 Removing and installing coolant pump

♦ Drip tray for workshop hoist - VAS 6208-
2. Coolant pump, regulation of cooling system 115

Scirocco 2015 ➤
Removing
WARNING


– Unscrew bolts -1-.
– Remove coolant pump -2-.
– Remove O-ring -3-.
Installing
. Volkswag
Install in reverse order of removal, observing
ksw
agenthe following: AG does
AG en
not
Vol gu
– Renew O-ring. by ara
ed nte
oris eo
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– Moisten new O-ring withs acoolant.
ut ra
c
s
• Installation position: plug in the housing faces downwards.
ce
le
un
pt
an
d
itte
Specified torques
y li
rm
ab
pe
ility
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,

ot
page 114
wit
, is n
h re
hole
spec
2.4 Removing and installing thermostat

es, in part or in w
t to the co
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
rrectness of i
nator; Removing and installing alternator .

l purpos
– Remove coolant pipes ⇒ page 120 .

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
– Release clip -1-.

– Pull off coolant hose -2-.

– Remove thermostat housing together with thermostat from
engine.
Installing
Note
Renew O-ring.
– Check coolant level ⇒ page 107 .

Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 114
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 119
2.5 Removing and installing coolant temper‐

ature sender - G62- wage
e ks s no
Vol t gu
Removing ed by ara
ris nte
utho eo
ra
a
WARNING ss c
ce
e
nl
pt
du
an

itte
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erm
ab

ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
• Engine cold.
– Briefly open filler cap for coolant expansion tank in order to
rrectness of i
reduce pressure in cooling system.

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
117
by lksw
cted agen
Prote 2. Coolant pump, regulation of cooling system
AG.
AG. Volkswagen AG d
agen oes
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Scirocco 2015 ➤ by
Vol not
gu
d ara
4-cylinder injection engine (2.0 l engine, oristurbocharger) Volkswagen R GmbH - Edition
e nte 09.2019
h eo
aut ra
c
– Disconnect electrical connector -1- at coolant
ss temperature
ce
e
sender - G62- .
nl
pt
du
an
itte
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erm
ab
ility
Note
ot p
wit
, is n
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Place a cloth underneath to catch escaping coolant.
hole
spec
es, in part or in w
– Release clip, and remove coolant temperature sender - G62- .
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia
Renew O-ring.
m
at
om
ion
c
in t
or
his
ate
do
priv
c
2.6 Removing and installing radiator outlet
um
for
en
ng
coolant temperature sender - G83-

t.
yi Co
Cop py
t. rig
gh
Removing
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING

• Engine cold.
– Briefly open filler cap of coolant expansion tank in order to
reduce pressure in cooling system.
insulation .
– Disconnect connector -2- on radiator outlet coolant tempera‐
ture sender - G83- .
Note
Place a cloth underneath to catch escaping coolant.
– Release clip -1-, and pull off radiator outlet coolant tempera‐
ture sender - G83- .
Installing
Note
Renew O-ring.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Scirocco 2015 ➤e o
ut
ss a Volkswagen R GmbH - Edition 09.2019 ra
c
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nl
pt
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3 Coolant pipes
itte
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erm
ab
ility
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⇒ “3.1 Assembly overview - coolant pipes”, page 119
wit
, is n
h re
⇒ “3.2 Removing and installing coolant pipes”, page 120
hole
spec
3.1 Assembly overview - coolant pipes
es, in part or in w
t to the co
1 - Bolt
rrectness of i
❑ 40 Nm
l purpos
2 - Bolt
❑ 23 Nm
nf
ercia
or
3 - Coolant pipe
m
m
atio
4 - Connection hose om
n in
or c
thi
e
5 - O-ring
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
6 - Union
yi Co
Cop py
t. rig
7 - Bolt
gh ht
pyri by
Vo
o
❑ 10 Nm
by c lksw
cted agen
Prote AG.
8 - Retaining clip
9 - O-ring
10 - Radiator outlet coolant -
G62-
⇒ page 117
11 - Connection hose
12 - Connector
16 - Coolant pipe
⇒ page 120
17 - Bolt
❑ 5 Nm
19 - Coolant pipe
20 - Bolt
❑ 10 Nm
21 - Thermostat housing
❑ With thermostat
❑ Checking thermostat ⇒ Vehicle diagnostic tester
❑ Starts to open at 87°C
22 - Bolt
❑ 15 Nm
3. Coolant pipes 119

Scirocco 2015 ➤
23 - Coolant pump
24 - Bolt
❑ 15 Nm
3.2 Removing and installing coolant pipes

♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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hole
Removing
spec
es, in part or in w

t to the co
– Remove turbocharger air recirculation valve - N249- -1- with

housing and hose ⇒ page 138 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
. Volkswagen AG
swagen AG Volkswagen doeRs
GmbH - Edition 09.2019
k not
Vol gu
d by ara
– Loosen clamp -1-. ris
e nte
utho eo
ra
– Unscrew bolt -2-. ss
a c
ce
le
un
pt
an
d
itte
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insulation .
erm
ab
ility
ot p
wit
is n
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ole,
spec
– Pull air intake pipe off charge air cooler, and remove it down‐
t to the co
wards.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Separate electrical connectors -arrows-.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen clamps -arrow-.

– Loosen clamp -A-.

– Pull off hose.
– Unscrew bolt -B-.
– Remove coolant pipe.
3. Coolant pipes 121

Scirocco 2015 ➤
– Release connector -A- from retainer.

– Loosen clamp -B-.
– Pull off hose.
– Unscrew bolts -C-.
– Remove coolant pipe.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 119
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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un
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itte
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erm
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
i
or
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te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
4 Radiator, radiator fan

⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123
⇒ “4.2 Removing and installing radiator”, page 124
⇒ “4.3 Removing and installing radiator fan V7 ”, page 124
⇒ “4.4 Removing and installing auxiliary radiator”, page 126
4.1 Assembly overview - radiator/radiator fan
1 - Cap
❑ Check using cooling
system tester - V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9-
❑ Pressure relief valve
must open at pressure
of 1.4 to 1.6 bar
2 - Electrical connector
3 - Bolt
❑ 5 Nm
4 - Expansion tank
❑ When renewing expan‐
sion tank and during
service operations, en‐ AG. Volkswagen AG d
sure that 2 silicate car‐ agen oes
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V
tridges ⇒ Electronic ed by gu
ara
Parts Catalogue are al‐ horis nte
eo
ways in expansion tank. s aut ra
c
Do not remove the sili‐ s
ce
le
cate cartridges.
un
pt
an
d
itte
❑ Check cooling system

y li
rm
ab
for leaks using cooling

pe
ility
system tester - V.A.G

ot
wit
, is n
1274 B- and adapter for

h re
cooling system tester -

hole
spec
V.A.G 1274/8-
es, in part or in w
t to the co
5 - Sealing strip
❑ Not fitted
rrectness of i
6 - O-ring
l purpos

7 - Lower coolant hose
nform
ercia
❑ To connection for ther‐

mostat.
m
a
com
tion in
8 - Nut
r
te o
thi
❑ 5 Nm
s
iva
do
r
rp
9 - Bolt
um
fo
en
ng
❑ 5 Nm
t.
yi Co
Cop py
t. rig
10 - Radiator fan 2 - V177- opyri
gh by
Vo
ht
❑ Removing and installing ⇒ page 124 by c lksw

cted agen
Prote AG.
11 - Radiator fan - V7-
❑ With radiator fan control unit - J293-
4. Radiator, radiator fan 123

Scirocco 2015 ➤
AG. Volkswagen AG d
13 - Radiator fan support agen oes
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by
❑ Removing and installing ⇒ page 124 rised ara
nte
ho eo
14 - Radiator/cooler aut ra
ss c
ce
le
un
pt
an
❑ After renewing, renew entire coolant.
d
itte
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rm
ab
15 - Upper coolant hose
pe
ility
ot
❑ To connection on cylinder head.
wit
, is n
h re
hole
spec
es, in part or in w
4.2 Removing and installing radiator
t to the co
Removing
rrectness of i
l purpos
– Move lock carrier to service position ⇒ General body repairs,

exterior; Rep. gr. 50 ; Lock carrier; Moving to and from service
position .
nform
mercia
– Removing fan support ⇒ page 124 .
a
com
tion in
r
te o
thi
s
iva
– Remove air duct.
do
r
rp
cum
fo
– Pull coolant hoses off radiator.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove radiator upwards.
Installing
Specified torques
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 123
4.3 Removing and installing radiator fan -

V7-

Scirocco 2015 ➤
♦ Tensioning strap - T10038-
Removing
– Unscrew upper fan support bolts -arrows-.
insulation .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Using tensioning strap - T10038- , pull engine approx. 15 mm

wit
, is n
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towards rear.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
125
cted agen
Prote AG.
4. Radiator, radiator fan
Scirocco 2015 ➤

– Unscrew lower fan support bolts -arrows-.
– Take out fan support from underneath.
– Disconnect electrical connector -1- and move electrical wires

clear.
– Unscrew nuts -arrows-.
– Remove fan.
Installing
Specified torques
4.4 Removing and installing auxiliary radia‐

tor
Removing
– Pull coolant hoses -1 and 2- off auxiliary radiator.
gen AG
. Volkswagen AG
d wa oes
olks not
– Remove front left wheel housingdliner
by ⇒ General body repairs,
V gu
ara
exterior; Rep. gr. 66 ; Wheelorhousing
ise liners; Removing and nte
eo
installing front wheel housing
au liners .
th ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co

– Remove auxiliary radiator -1-.
rrectness of i
Installing
l purpos

nform
ercia

m
a
com
Specified torques
ion in
r
te o
thi

s
iva
do
r
Auxiliary radiator nuts 9 Nm

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤
21 – Turbocharging/supercharging
1 Turbocharger olksw
agen
AG. Volkswagen AG d
oes
not
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by ara
⇒ “1.1 Assembly overview - turbocharger”,
rised page 127 nte
ho eo
ut
⇒ “1.2 Removing and installing
ss a turbocharger”, page 129 ra
c
ce
le
⇒ “1.3 Checking vacuum unit for turbocharger”, page 136 un
pt
an
d
itte
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1.1 Assembly overview - turbocharger
erm
ab
ility
ot p
⇒ “1.1.1 Assembly overview – turbocharger, part I”, page 127
wit
is n
h re
ole,
⇒ “1.1.2 Assembly overview – turbocharger, part II”, page 128
spec
1.1.1 Assembly overview – turbocharger, part I
t to the co
1 - Seal
rrectne
ss
2 - Nuts
o
cial p
f i
nform
mer
❑ Lubricate exhaust mani‐
atio
fold studs with high-tem‐
om
n
perature paste ⇒ Elec‐
c
i
or
n thi
tronic Parts Catalogue
te
sd
a
(ETKA)
iv
o
pr
cum
r
❑ 20 Nm
fo
en
ng
t.
yi Co
3 - Banjo bolt Cop py
t. rig
gh
❑ 35 Nm
ht
pyri by
Vo
o
by c lksw
cted
4 - Seal
agen
Prote AG.

5 - Bolt
❑ 9 Nm
6 - Bolt
❑ On coolant return line
only fitted with 2 retain‐
ers
❑ 23 Nm
7 - Coolant distribution housing
❑ Gradual introduction of
coolant return lines with
one retainer
8 - Turbocharger
⇒ page 129
9 - Bracket
10 - Bolt
❑ Coat bolt with high-temperature paste; ⇒ Electronic Parts Catalogue (ETKA)
❑ 30 Nm
11 - Bolt
❑ Coat bolt with high-temperature paste; ⇒ Electronic Parts Catalogue (ETKA)
❑ 30 Nm
1. Turbocharger 127
Scirocco 2015 ➤
12 - Bracket
13 - Bolt
❑ 23 Nm
14 - Nut
❑ Renew after removal n AG. Volkswagen AG do
swage es n
❑ Do not loosen to remove turbocharger
byV
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ed ran
❑ Lubricate exhaust manifoldhostuds
ris with high-temperature paste ⇒ Electronic tee Parts Catalogue (ETKA)
ut or
❑ 30 Nm ss
a ac
ce
le
15 - Clamping rail
un
pt
an
d
itte
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ab
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ility
1.1.2 Assembly overview – turbocharger, part II
ot
wit
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hole
spec
1 - Turbocharger
es, in part or in w
t to the co
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
rrectness of i
unit as one unit
l purpos

⇒ page 129
nform
ercia
2 - Line
m
❑ To activated charcoal fil‐
a
com
ti
ter
on in
r
te o
thi
3 - Seal
s
iva
❑ Renew after removal do

r
rp
cum
fo
en
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4 - Bolt
n
t.
yi Co
op py
❑ 9 Nm t. C rig
gh ht
pyri by
5 - Heat shield
co Vo
by lksw
cted agen
Prote AG.
6 - Crankcase breather line
7 - Intake hose
❑ Note installation posi‐
tion ⇒ page 129
8 - Seal
9 - To turbocharger air recircu‐
lation valve - N249-
❑ ⇒ Item 29 (page 140)
10 - Hose clamp
11 - Seal
tion ⇒ page 129
12 - Vacuum unit for turbo‐
charger
13 - Connection
14 - Hose
15 - Seal
128 Rep. gr.21 - Turbocharging/supercharging

Scirocco 2015 ➤
16 - Banjo bolt
❑ 8 Nm
17 - Hose
18 - Bolt
❑ 3 Nm
AG. Volkswagen AG d
19 - Charge pressure control solenoid valvelk-swN75-
agen oes
not
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20 - Hose ris
edb ara
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21 - Seal au ra
c
ss
ce
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nl
pt
du
an
22 - Connection
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23 - Retaining clip
ility
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24 - Bolt
h re
hole
❑ 9 Nm
spec
es, in part or in w
t to the co
Intake hose installation position
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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for
en
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Cop py
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rig ht
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cted agen
Prote AG.
1.2 Removing and installing turbocharger

♦ Pliers for spring-type clips - VAS 5024 A-
1. Turbocharger 129
Scirocco 2015 ➤
♦ Tensioning strap - T10038-
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
must be performed:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
If foreign objects are found in the wcharge
agen air system,Athe
AG. Volkswagen G d charg‐
oes
ed air routing must be cleaned y V and the charge air cooler must
olks not
gu
be renewed, if necessary. ise
d b ara
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ac
ss
Removing
ce
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un
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d

itte
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pe

ility
ot
wit
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– Remove intake hose.

h re
hole
spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tio
– Pull charge air hose -arrow- from charge air cooler.

n in
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te o
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iva
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Cop py
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Vo
co lksw
by
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Prote AG.

Scirocco 2015 ➤

– Remove charge air pipe.
– Disconnect electrical connectors -1 and 2-.

– Unclip wiring harness.
– Remove connection from turbocharger.
– Disconnect connector for lambda probe - G39- -arrow-.

– Lay wiring harness to one side.
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– Pull connectors -arrows- off ignition coils.
ce
le
un
pt
an
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– Move wiring harness aside.

itte
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rm
ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
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thi
s
iva
do
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t.
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131
op Vo
by c lksw
Prote
cted AG.
agen 1. Turbocharger
Scirocco 2015 ➤

– Pull off coolant hose.
AG. Volkswagen AG d
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or eo
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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n in
or c
thi
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sd
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– Pull upper coolant hose from heat exchanger -arrow-.

rp
cu
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

– Remove heat shield together with coolant pipe.

Scirocco 2015 ➤

– Pull crankcase breather -2- off cylinder head cover, and re‐
move it.
– Release clip -3- and detach hose.
en AG . Volkswag
– Unscrew both upper front exhaust pipe/turbocharger
ksw
agen
AG nuts. does
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spec
es, in part or in w
t to the co
rrectness of i
– Remove heat shield for right drive shaft.
l purpos
nform
mercia
a
com
tion in
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Cop py
– Unscrew both lower front exhaust pipe/turbocharger nuts. ht. rig
rig ht
py by
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Prote AG.
1. Turbocharger 133
Scirocco 2015 ➤
– Disconnect exhaust system from clamping sleeve -arrows-.

– Pull front exhaust pipe from turbocharger and push backwards
slightly.
AG. Volkswagen AG d
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erm
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spec
t to the co
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cial p
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mer

atio
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rig ht
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by lksw
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Prote AG.

Scirocco 2015 ➤

– Remove turbocharger support.
Note
The following procedure is necessary to provide more space be‐

tween the cylinder head and plenum chamber bulkhead.

AG. Volkswagen AG d
agen oes
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au ra
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un
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Using tensioning strap - T10038- , pull engine approx. 20 mm
t to the co
towards rear.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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n
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Cop py
– Pull off coolant hose.
t. rig
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pyri by
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by
cted agen
Prote AG.
1. Turbocharger 135
Scirocco 2015 ➤
– Unscrew bolt -1- for coolant pipe.
Note
♦ The clamping strip nuts need not be loosened.

♦ Bolt -1- is only fitted on coolant pipes with 2 retainers.
– Unscrew upper nuts -arrows-.

– Remove turbocharger and exhaust manifold upwards.
Installing
AG. Volkswagen AG d
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not
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ed
Renew gaskets,
thorisseals and self-locking nuts. nte
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– Fill turbocharger with engine oil at oil supply line connection. ce
le
un
pt
an
d
– After installing turbocharger, run engine at idling speed for

itte
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about 1 minute to ensure that oil is supplied to the turbocharg‐ ab

pe
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er.
ot
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Specified torques
h re
hole
spec
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 127

es, in part or in w
t to the co
♦ ⇒ “3.1 Assembly overview - oil circuit”, page 98
1.3 Checking vacuum unit for turbocharger

rrectness of i
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nform
mercia
a
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tion in
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Cop py
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pyri by
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Test conditions
♦ Hose from turbocharger via charge pressure control solenoid
valve - N75- to vacuum unit must have through-flow (not
blocked).
♦ Charge pressure control solenoid valve - N75- must be OK.
Procedure

Scirocco 2015 ➤
– Connect hand vacuum pump - VAS 6213- to vacuum unit

-arrow-.
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
– Move slide ring -1- on hand ut vacuum pump - VAS 6213- to po‐
ho eo
ra
a
sition -B- for “pressure”.
ss c
ce
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un
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an
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Caution
itte
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erm
ab
ility
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The pressure must not exceed 750 mbar! If the pressure is
wit
is n
exceeded, the vacuum unit can be damaged.
h re
ole,
spec
t to the co
rrectne
– Operate hand vacuum pump - VAS 6213- repeatedly, observ‐
s
ing linkage.
s o
cial p
f in
The linkage -A- should start to move at a pressure of approx.
form
mer
300 mbar and be at its limit stop at a pressure of approx.
atio
700 mbar.
om
n
c
i
The stroke of the rod is approx. 10 mm.
or
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1. Turbocharger 137
Scirocco 2015 ➤
2 Charge air system

⇒ “2.1 Schematic overview - charge air system”, page 138
⇒ “2.2 Assembly overview - charge air system”, page 138
⇒ “2.3 Assembly overview - charge-air hose connections”,
page 140
⇒ “2.4 Removing and installing charge air cooler”, page 141
⇒ “2.5 Checking charge air system for leaks”, page 142
2.1 Schematic overview - charge air system
1 - Turbocharger air recircula‐

tion valve - N249-
2 - Throttle valve module -
J338-
3 - Pressure regulating valve
for crankcase breather
4 - To activated charcoal filter
AG. Volkswagen AG d
agen
5 - Vacuum unit for charge Volksw
oes
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pressure control d by ara
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6 - Charge pressure control auth
ra
solenoid valve - N75- ss c
ce
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un
pt
7 - Turbocharger
an
d
itte
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8 - Brake servo
ab
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ility
ot
9 - Non-return valve
wit
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10 - Air mass meter - G70-
hole
spec
es, in part or in w
11 - Air filter
t to the co
12 - Coolant connection
13 - Vacuum pump
rrectness of i
14 - Non-return valve
l purpos
15 - Oil filter bracket

nform
ercia
16 - Activated charcoal filter

solenoid valve 1 - N80-
m
a
com
tion in
17 - Dual non-return valve

r
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18 - Charge air pressure send‐

iva
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er - G31-
rp
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19 - Charge air cooler

t.
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Prote AG.
2.2 Assembly overview - charge air system
Caution
The screw-type clips on the charge air pipes must be tightened

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

Scirocco 2015 ➤
1 - Bolt
❑ 5 Nm
2 - Mountings
❑ for charge air cooler
3 - Charge air cooler
⇒ page 141
4 - Hose clamp
❑ 5.5 Nm
5 - Bolt
❑ 10 Nm
6 - Charge air pipe
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 140
7 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 140
8 - Hose clamp
9 - To intake hose lkswage es n
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byV ua
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10 - Charge air hose o
ir se tee
th or
❑ To throttle valve moduless au ac
- J338- .
ce
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un
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an
11 - Hose clamp
d
itte
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erm
ab
❑ 5.5 Nm
ility
ot p
12 - Charge air pipe wit

is n
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ole,
13 - Bolt
spec
❑ 10 Nm
t to the co
14 - Hose clamp
❑ 5.5 Nm
rrectne
15 - Charge air hose

s
16 - Hose clamp
s o
cial p
❑ 5.5 Nm
inform
mer
17 - Seal
atio
m

o
n
c
i
or
n thi
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18 - Charge air pressure sender - G31-

t
sd
iva
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pr
19 - Bolts
um
r
fo
en
ng
❑ 5 Nm
t.
yi Co
Cop py
. rig
20 - Bolt
t
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pyri by
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❑ 10 Nm
c by lksw
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Prote AG.
2. Charge air system 139

Scirocco 2015 ➤
21 - Hose clamp AG. Volkswagen AG d

agen oes
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22 - Hose d by
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23 - Hose clamp
ut
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s a c
s
24 - Housing
ce
le
un
pt
an
25 - Turbocharger air recirculation valve - N249-
d
itte
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erm
ab
ility
ot p
26 - Bolt
wit
is n
h re
❑ 7 Nm
ole,
spec
27 - Seal
t to the co
28 - Hose clamp
rrectne
29 - Hose
ss o
cial p
f in
Installation location of turbocharger air recirculation valve - N249-
form
mer
atio
om
n
c
i
or
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te
sd
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pr
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t.
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Cop py
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by c lksw
cted agen
Prote AG.
2.3 Assembly overview - charge-air hose

connections
Caution
The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe assembly instructions.

Scirocco 2015 ➤
Removing
– Loosen locking lug -A-.
– Release plug-in connector by pulling out retaining clip
-arrow-.
Installing
– On renewing oil seal in charge air hose groove; ensure that oil
seal is seated completely in groove all around and is not twis‐
ted.
– Coat sealing surface and oil seal with oil.
– Bring retaining clip to release position -1-.

– Push charge air hose into coupling as far as stop.
– Bring retaining clip to locking position -2- and then press
charge air hose again.
– Pull on hose to ensure that plug-in connector is properly seat‐
ed and engaged.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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nl
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du
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ility
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hole
spec
es, in part or in w
t to the co
2.4 Removing and installing charge air cool‐
er rrectness of i
Removing
l purpos
– Remove bumper cover ⇒ General body repairs, exterior; Rep.

gr. 63 ; Front bumper; Removing and installing front bumper
nf
ercia
cover .
orm
m
atio
– Release clips -arrows-.

om
n in
or c
– Remove air intake hose.

thi
te
sd
iva
– Removing radiator ⇒ page 124 .

o
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cu
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f
– Remove air ducts from lock carrier ⇒ General body repairs,

en
ng
t.
yi Co
exterior; Rep. gr. 50 ; Lock carrier; Assembly overview – lock Cop py
carrier .
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤
Note
The condenser bolts are difficult to access. With the aid of a 2nd
mechanic, lift the charge air cooler out of the radiator mountings.
The charge air cooler can now be moved back and forth a little to
allow access to the bolts.
– On the right-hand side of the charge air cooler, unscrew bolt

-arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Secure condenser to lock carrier with cable ties.
– Take out charge air cooler from underneath. rrectness of i
Installing
l purpos

nf
ercia
Specified torques
orm
m
atio
♦ ⇒ “2.2 Assembly overview - charge air system”, page 138

om
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c

or
thi
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o
2.5 Checking charge air system for leaks

f
en
ng
t.
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op py
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pyri by
Vo
♦ Charge air system tester - V.A.G 1687-
co lksw
by
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Prote AG.
♦ Adapter - V.A.G 1687/5-

Procedure
Rep. gr. 50 ; Body - front, noise insulation .

Scirocco 2015 ➤
– Release securing clip -A-.

– Pull hose -B- off charge air pipe.
– Connect adapter - V.A.G 1687/5- onto charge air hose -A- and
turn approx. 90° -B-.
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- completely.

– Close valves -3 and 4-.
Note
AG. Volkswagen AG d
agen oes
ksw
To turn the pressure regulating valve -2- the knobbymust
Vol
be pulled not
gu
ara
upwards. rised
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Connect charge air system tester - V.A.G 1687- as shown.

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

Scirocco 2015 ➤
– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
Note
AG. Volkswagen AG d
If there is water in the inspection glass, drain it via the water drainolkswagen oes
not
plug -6-. db
yV gu
ara
e nte
ris
tho eo
– Open valve -3-. ss
au ra
c
ce
e
– Pressure control valve -2-, set pressure to 0.5 bar.
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
The pressure must not exceed 0.5 bar. If the pressure is too
h re
hole
high this can cause damage to the engine.
spec
es, in part or in w
t to the co
– Open valve -4-, and wait until test circuit has filled; if neces‐
sary, adjust pressure to 0.5 bar.
rrectness of i
– Check the charge air system for leaks by listening, touching,
l purpos
with commercially available leak detector spray or using ultra‐

sonic tester - V.A.G 1842- .
nf
ercia
orm
m
Note
atio
om
n in
or c
♦ A small amount of air escapes through the valves and enters
thi
te
the engine. Therefore a holding pressure test is not possible.
sd
iva
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rp
cu
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
o
m
f
en
ng
instructions
t.
yi Co
Cop py
. rig
♦ Depressurise test circuit by detaching coupling from adapter -
ht ht
rig by
py
V.A.G 1687/5- before removing adapter. co Vo
by lksw
cted agen
Prote
♦ Hose connections and hoses for charge air system must be
AG.
free of oil and grease before assembly.

Scirocco 2015 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Releasing high pressure in fuel system”, page 145
1.1 Releasing high pressure in fuel system
WARNING
Risk of injury due to fuel which is under very high pressure.

♦ The injection system consists of a high-pressure section
(maximum approx. 150 bar) and a low-pressure section
(approx. 6 bar).
♦ Prior to opening the high-pressure section, e.g. when re‐
moving the high-pressure pump, fuel rail, injectors, fuel
pipes, or the fuel pressure sender - G247- , the fuel pres‐
sure in the high-pressure system must be reduced to a
specified value of approx. 6 bar. The appropriate proce‐
dure is described as follows.
AG. Volkswagen AG d
agen oes
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d b ara
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un
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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
145
Prote AG.
1. Injection system
Scirocco 2015 ➤
– Disconnect electrical connector -arrow- from fuel pressure

regulating valve - N276- .
– Allow engine to idle for approx. 10 seconds.
Note
♦ When the engine is idling and the electrical connector is pulled

off the fuel pressure regulating valve - N276- , the pressure in
the high-pressure system will drop to approx. 6 bar.
♦ When the high-pressure is reduced, the high-pressure system
must be opened, because the fuel pressure can rise by warm‐
ing up.
– Switch off ignition.
WARNING
Risk of injury, avoid skin contact with fuel.

♦ Wear eye protection and protective clothing when opening
the fuel system.
♦ Wrap a clean cloth around the connection to catch escap‐
ing fuel before opening the high-pressure system.
gen AG
. Volkswagen AG
a does
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y Vol gu
db ara
ise nte
– Now place a clean cloth aroundththeor connection, and carefully eo
open the connection to release au the residual pressure of ap‐ ra
c
ss
prox. 6 bar. Catch the escaping fuel. ce
e
nl
pt
du
an
– After completing work, read event memory of engine control
itte
y li
unit. Delete all event memory entries which may have occur‐
erm
ab
red by unplugging connector ⇒ Vehicle diagnostic tester.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co

rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
146 Rep. gr.24 - Mixture preparation - injection

Scirocco 2015 ➤
2 Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147
⇒ “2.2 Removing and installing injectors”, page 148
⇒ “2.3 Removing and installing fuel rail”, page 150
⇒ “2.4 Renewing seals on injectors”, page 151
2.1 Assembly overview - fuel rail with injectors
1 - Injector -N30- / -N33-

⇒ page 148
2 - Bolt AG. Volkswagen AG d
agen oes
❑ 8 Nm Volksw not
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d by ara
e
3 - Fuel distributor horis nte
eo
ut
❑ Removing and installing ss a ra
c
⇒ page 150
ce
e
nl
pt
du
an
4 - Low pressure fuel hose
itte
y li
erm
ab
❑ To high-pressure pump
ility
ot p
wit
5 - Pressure limiting valve
, is n
h re
❑ To remove and install,
hole
spec
remove intake manifold
es, in part or in w
⇒ page 158
t to the co
❑ 30 Nm
6 - Panel nut
rrectness of i
7 - Low pressure pipe
l purpos
❑ Counterhold pressure
limiting valve when loos‐
nf
ercia
ening union nut. orm

m
❑ Before installing, check

atio
m
torque of pressure limit‐

o
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ing valve
thi
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sd
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❑ Install free of tension.

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❑ Tighten union nut to

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ng
22 Nm.
t.
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Cop py
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8 - Bracket opyri
gh by
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ht
by c lksw
9 - High-pressure pipe Prote
cted AG.
agen
❑ Counterhold threaded
connection when loos‐
ening union nut.
❑ Before installing, check torque of threaded connection
❑ Install free of tension.
❑ Tighten union nuts to 27 Nm.
10 - Bolt
❑ 3 Nm
❑ For injectors.
2. Injectors 147
Scirocco 2015 ➤
14 - Cable channel
15 - Clip
❑ Attach on lower right sleeve of intake manifold
❑ for Hall sender - G40-
❑ For fuel pressure sender - G247- . AG. Volkswagen AG do
agen w es n
olks ot g
18 - Bolt ed
byV ua
ran
ris
❑ 5 Nm tho
tee
or
au ac
19 - Fuel pressure ss
sender - G247-
ce
e
nl
pt
❑ Coat thread and sealing taper with clean engine oil.
du
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ility
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❑ 22 Nm
h re
hole
spec
20 - Connecting union
es, in part or in w
❑ 30 Nm
t to the co
rrectness of i
2.2 Removing and installing injectors
l purpos

♦ Tool set - T10133-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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pyri by
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co lksw
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cted agen
Prote AG.
Note
Puller tool T10133/2 has been modified and is now designated

puller T10133/2 A . If the new tool is not yet available in the work‐
shop, perform the modification yourself.
Rework puller tool T10133/2 to make puller tool T10133/2 A .

♦ Round file approx. 6 mm
– File out a semicircle as illustrated. Tool can be pushed further
through semicircle onto injector. Tool has larger contact sur‐
face area as a result.

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agen oes
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oris Scirocco 2015 nt➤
ee
th o
s au Volkswagen R GmbH - Edition 09.2019 r ac
s
ce
e
nl
pt
– For identification purposes, mark the modified tool with the
du
an
itte
letter “A” after the tool number.
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Injector components
orm
1- Radial compensation element (renew) m
atio
om
n in
c
2- Combustion chamber ring seal (Teflon ring seal) - renew;
or
thi
e
when fitting, do not grease ring or use any other lubricant.
t
sd
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cu
3- Groove in injector.
o
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4- Support washer (renew).
Co
Cop py
ht. rig
5- O-ring (renew; to install, lightly lubricate with clean engine rig ht
py by
oil).
co Vo
by lksw
cted agen
Prote AG.
6- Support ring
Note
When the injector is fitted, the radial compensation element -1- is

clipped into the support ring -6-. To remove the injector, the sup‐
port ring must be removed from the injector so that the puller -
T10133/2- can be inserted into the groove on the injector -3-.
Removing
– Seal intake ports with a clean cloth.
– Use a screwdriver to move radial compensation element re‐

taining lugs to side and pull support ring from injector.
Note
The retaining hooks of radial compensation element are damaged

by this action (retaining hooks bend or break). The radial com‐
pensation element must be renewed before injector is refitted.
2. Injectors 149
Scirocco 2015 ➤
– Insert puller -T10133/2A- into groove in injector.

– Then, fit removal tool -T10133/16- .
– Pull out injector by turning bolt -1-.
Installing
Note
♦ Do not oil or grease the Teflon seal on the injector.

♦ It is possible that an open inlet valve hinders cleaning. In this
case, turn engine by hand at crankshaft
en AG. V
olkswagen Ausing
G
a spanner.
ag does
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– rise
Clean high-pressure injector bores in cylinder head thoroughly
nte
tho eo
with a nylon
s au brush - T10133/4- . ra
c
s
ce
– Renew O-ring, radial compensation element, support washer
le
un
pt
and Teflon seal of injector ⇒ page 151 .
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert injector in bore in cylinder head to stop using drift -

l purpos
T10133/9- .
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
t. rig
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by
cted
– Ensure injectors are positioned correctly in cylinder head.
agen
Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 147
2.3 Removing and installing fuel rail

Removing
– Remove activated charcoal filter hoses.

Scirocco 2015 ➤

– Pull hose connection -1- off intake manifold.

gen AG
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d wa oes
olks not
– Unscrew bolts -arrows-. byV gu
ara
ed nte
ris
– Loosen union nuts of boththo fuel pipes -2 and 3-. eo
au ra
c
ss
– Counterhold on pressure limiting valve.
ce
e
nl
pt
du
– Carefully lever off linkage from intake manifold flap motor -
an
itte
y li
V157- -4-.
erm
ab
ility
ot p
wit
, is n
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– Remove fuel rail from intake manifold.
hole
spec
Installing
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos

nform
ercia
2.4 Renewing seals on injectors

m
at
om
ion

c
in t
or
his
te
♦ Tool set - T10133-

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Do not lubricate the Teflon ring.
Procedure
– Carefully remove old Teflon ring using a suitable tool (e.g. cut
open ring using razor blade, or prise open ring with small
screwdriver and then pull off forwards). It is essential to ensure
that the groove and continuous ridge in groove surface are not
damaged.
2. Injectors 151
Scirocco 2015 ➤
– Carefully clean injector in area of oil seal -arrow- and remove

existing deposits (carbon) with a brass brush.
– Carefully cut oil seal open with a knife.
– Clean oil seal groove.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
aut ra
ss c
ce
– Position new oil seal on assembly cone - T10133/5- and push le
un
pt
an
d
oil seal onto assembly cone - T10133/6- as far as possible with

itte
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assembly sleeve - T10133/5- .
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f i
– Turn assembly sleeve - T10133/6- over and push oil seal onto
nform
end of assembly cone - T10133/5- .
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit assembly cone - T10133/5- on injector and push oil seal

onto injector using assembly sleeve - T10133/6- .
– Remove assembly cone - T10133/5- and push oil seal into
groove with assembly sleeve - T10133/6- .

Scirocco 2015 ➤
– Push calibration sleeve - T10133/7- onto injector to stop and

simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve - T10133/7- off again, turning in oppo‐
site direction.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
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– Push calibration sleeve - T10133/8- orisonto
e injector to stop and nte
simultaneously turn it slightly (approx.
auth 180°). eo
ra
ss c
– Pull calibration sleeve - T10133/8- off again, turning in oppo‐
ce
le
un
pt
site direction.
an
d
itte
y li
– Renew O-ring on injector and on support washer.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Attach support ring back to injector -1-.
– Clip radial compensation element -2- into support ring.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Injectors 153
Scirocco 2015 ➤
3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 154
⇒ “3.2 Removing and installing air filter housing”, page 155
3.1 Assembly overview - air filter housing
1 - Air mass meter - G70-

tion ⇒ page 155
⇒ page 166
2 - Bolt
❑ 3 Nm
3 - Upper part of air filter/en‐
gine cover panel
❑ Remove salt residues, n AG. Volkswagen AG do
swage es n
dirt and leaves from air byV
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ua
filter lower section. ir se
d ran
tee
ho
❑ Removing and installing aut or
ac
⇒ page 155 ss
ce
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nl
pt
du
4 - Spring-type clip
an
itte
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erm
ab
5 - Intake air guide
ility
ot p
6 - Filter element
wit
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h re
❑ Always use Genuine
hole
spec
Part for air filter element
es, in part or in w
t to the co
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet ; Service tables
rrectness of i
7 - Air filter lower part
l purpos
❑ Remove salt residues,

dirt and leaves from air
filter lower section. nf
ercia
orm
8 - Bolt
m
atio
m
❑ 3 Nm
o
n in
or c
thi
e
9 - Heat shield
t
sd
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10 - Rubber grommet
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f
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ng
❑ Observe assembly
t.
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11 - Intake hose cop Vo
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❑ Observe assembly marking Prote AG.
❑ Check for soiling and leaves in air hose.

Scirocco 2015 ➤
Installation position of seal -2- of air mass meter - G70- -1-

Smooth side of seal must be in contact with air mass meter -
G70- , see magnified view.
AG. Volkswagen AG d
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un
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erm
ab
ility
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wit
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ole,
spec
3.2 Removing and installing air filter hous‐
t to the co
ing
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Hose clamp pliers - VAS 6340-
3. Air filter 155

Scirocco 2015 ➤
Removing
– Using hose clip pliers - VAS 6340- , loosen spring-type clip
-B-.
– Pull air duct off engine cover panel -A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– Unplug electrical connector -2- from air mass meter
ss a- G70- . c
ce
– Loosen clips -arrows A.- le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Unclip hose from attachments -2-.
s o
cial p
f i
– Unclip and lift engine cover panel successively from mounting
nform
points -arrow 4-, -arrow 5-, -arrow 6- and finally -arrow 3-.
mer
atio
m
Installing
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
Note
t.
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Cop py
t. rig
gh
The engine cover panel rubber mountings -arrows- may not be
ht
pyri by
Vo
lubricated or greased before installation.
co lksw
by
cted agen
Prote AG.
– Renew rubber mountings.
– During installation, ensure that the 4 rubber mountings

-arrows- are inserted correctly.
– Position engine cover panel in installation position and press
rubber mountings simultaneously onto retaining pins.
Specified torques
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 154

Scirocco 2015 ➤
4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 157
⇒ “4.2 Removing and installing intake manifold”, page 158
⇒ “4.3 Removing and installing intake manifold flap motor V157
”, page 160
⇒ “4.4 Removing and installing throttle valve module J338 ”, page
162 agen
AG. Volkswagen AG d
o
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Vol ot g
4.1 Assembly overview - intake manifold ris
ed by ua
ran
tee
tho or
au ac
ss
1 - Nut
ce
e
nl
pt
du
❑ 10 Nm
an
itte
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erm
ab
2 - Clamp
ility
ot p
wit
3 - Bolt
, is n
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❑ 3 Nm
hole
spec
es, in part or in w
4 - Stud
t to the co
❑ 10 Nm
5 - Seal
rrectness of i
l purpos
6 - Intake manifold
❑ With intake manifold
nf
ercia
flaps
orm
m
atio
om
⇒ page 158
n in
or c
thi
e
7 - Coupling rod
t
sd
iva
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cu
8 - Intake manifold flap motor -
o
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f
en
ng
V157- and intake manifold flap

t.
yi Co
potentiometer - G336- Cop py
t. rig
gh
ht
pyri by
Vo
o
⇒ page 160 by c lksw
cted agen
Prote AG.
9 - Bolt
❑ 7 Nm
10 - To activated charcoal filter
11 - Hose
12 - Activated charcoal filter
solenoid valve 1 - N80-
13 - Hose
14 - Dual non-return valve
15 - Intake manifold support
16 - Bolt
❑ 25 Nm
17 - Nut
❑ 10 Nm
4. Intake manifold 157

Scirocco 2015 ➤
18 - Bonded rubber bush

19 - Throttle valve module - J338-
❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender 1 for throttle valve drive
(electric throttle operation) - G187- and angle sender 2 for throttle valve drive (electric throttle operation)
- G188- .
20 - Bolt
❑ 7 Nm
21 - Seal
❑ Renew if damaged
22 - Bolt
❑ 5 Nm
23 - Intake air temperature sender - G42-
24 - Bolt AG. Volkswagen AG d
agen
❑ 10 Nm Volksw
oes
not
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d by ara
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or eo
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aut ra
4.2 Removing and installing intake manifold
ss c ce
le
un
pt
an
Removing
d
itte
y li
rm
ab
– Remove throttle valve module - J338- ⇒ page 162 .

pe
ility
ot
wit
– Disconnect all necessary electrical connectors.

, is n
h re
hole
– Pull vacuum hose between intake manifold and vacuum pump

spec
from intake manifold.

es, in part or in w
t to the co
WARNING
rrectness of i

l purpos

Before loosening hose connections, wrap a cloth around the
connection. Release pressure by carefully pulling hose off con‐
nform
ercia
nection.
m
a
com
Observe the safety precautions when releasing fuel pressure

ion in
in the high-pressure system ⇒ page 145 .

r
te o
thi
s
iva
do
r
rp
cum
– Disconnect fuel supply line -2-.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Scirocco 2015 ➤
– Loosen clamp -2-.

– Pull off breather line.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Pull off vacuum lines -arrows-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Connections of old high-pressure pumps:

or
thi
te
sd
a
– Release both fuel lines from high-pressure pump.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Connections of new high-pressure pumps:


Scirocco 2015 ➤
– Release coolant pipe and dipstick guide -arrows- from intake

manifold.
– Pull dipstick guide in direction of -arrow- upwards off engine.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Unscrew bolts -arrows-. ut
ho eo
ra
s a c
– Remove intake manifold support. s
ce
e
nl
pt
du
– Disconnect connector -arrow- from fuel pressure sender -
an
itte
y li
G247- .
erm
ab
ility
ot p
– Unscrew all bolts from intake manifold.
wit
, is n
h re
– Carefully pull intake manifold with fuel rail from cylinder head.
hole
spec
Installing
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
4.3 Removing and installing intake manifold
nf
ercia
o
flap motor - V157-
rm
m
atio
om
n in
or c
thi
e

t
sd
iva
o
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rp
cu
o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing

Scirocco 2015 ➤

– Remove air duct.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
housing and hose ⇒ page 138 . es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Pull off vacuum lines -arrows-.
o
m
f
en
ng
t.
yi
– Disconnect following connectors:
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note Prote
cted AG.
agen
Use assembly tool - T10118- to facilitate opening of connectors

which are less accessible
♦ Connector for intake manifold flap motor - V157-

♦ Electrical connection for activated charcoal filter system sole‐
noid valve 1 - N80-
♦ Connector for intake manifold pressure sender - G71-
♦ Connector for throttle valve module - J338-
♦ Connector for fuel pressure sender for low pressure - G410-
– Disconnect additional connectors -arrows-.

– Loosen cable retainer -A-, and place complete wiring harness
to side.

Scirocco 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
– Prise coupling rod -arrow- off intake manifold flap motor - un
pt
an
d
V157- .
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Note
atio
om
n
c
i
The rear bolt -arrow- can only be unscrewed with a ratchet handle.
or
n thi
e
The space between the bolt and the water pipe is very constricted.
t
sd
iva
o
pr
cum
r
fo
– Remove intake manifold flap motor - V157- from intake mani‐
en
ng
t.
yi
fold.
Co
Cop py
t. rig
gh ht
Installing yri
p by
co Vo
by lksw
cted
agen
Prote AG.
If the intake manifold flap motor - V157- or the intake manifold

were renewed, the intake manifold flap potentiometer - G336-
must be adapted to the engine control unit - J623- ⇒ Vehicle
diagnostic tester.
Specified torques
4.4 Removing and installing throttle valve

module - J338-
Removing

Scirocco 2015 ➤

housing and hose ⇒ page 138 .

AG. Volkswagen AG d
– Unscrew bolt -2-. agen oes
olksw not
V gu
by ara
rised
nte
Rep. gr. 50 ; Body - front, noise insulation . aut
ho eo
ra
ss c
ce
le
un
pt
an
d

itte
y li
rm
ab
– Pull air intake pipe off charge air cooler, and remove it down‐
pe
ility
wards.
ot
wit
, is n
h re
– Unscrew 4 bolts, and remove throttle valve module - J338- .
hole
spec
Cleaning throttle valve module - J338-
es, in part or in w
t to the co
Note
rrectness of i
♦ Note safety precautions ⇒ page 2 .
l purpos
♦ Observe rules for cleanliness ⇒ page 4 .
nform
ercia
♦ When cleaning the throttle valve housing, take care not to

scratch it.
m
a
com
tion in
r
te o
thi
– Open throttle valve by hand and block open with a suitable
s
iva
do
object -arrow-.
r
rp
cum
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
Acetone is highly inflammable. Observe accident prevention
o
by c lksw
cted agen
regulations and safety notes when handling highly inflammable Prote AG.
fluids. Do not use compressed air to clean throttle valve. Wear
protective goggles and protective clothing to avoid injury and
contact with the skin.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Scirocco 2015 ➤ ut
h o eo
ra
a
4-cylinder injection engine (2.0
ss l engine, turbocharger) Volkswagen R GmbH - Edition c 09.2019
ce
le
un
pt
– Thoroughly clean throttle valve housing, especially around
an
d
itte
y li
closed throttle valve, using commercially available acetone
rm
ab
and a cleaning brush.
pe
ility
ot
wit
, is n
– Wipe the inside of the throttle valve housing with a lint-free
h re
cloth.
hole
spec
– Allow acetone to dry off completely. es, in part or in w
t to the co
Installing
rrectness of i
– Adapt engine control unit - J623- to throttle valve module
l purpos
⇒ Vehicle diagnostic tester.

Specified torques
nform
ercia

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

Scirocco 2015 ➤
5 Senders and sensors

⇒ “5.1 Assembly overview - actuator for structure-borne sound
and control unit for structure-borne sound”, page 165
⇒ “5.2 Removing and installing air mass meter G70 ”, page 166
⇒ “5.3 Removing and installing fuel pressure sender G247 ”, page
166
⇒ “5.4 Checking fuel pressure sender G247 ”, page 167
5.1 Assembly overview - actuator for structure-borne sound and control unit for
structure-borne sound
1 - Control unit for structure-

borne sound - J869-
❑ Fitting location: in ple‐
num chamber
❑ To remove or install, re‐
move plenum chamber
cover ⇒ General body
repairs, exterior; Rep.
gr. 50 ; Plenum cham‐ gen AG
. Volkswagen AG
does
swa
ber bulkhead; Remov‐ y Volk not
gu
ing and installing ple‐ risedb ara
nte
num chamber cover ut
ho eo
r a ac
ss
2 - Bolts
ce
e
nl
pt
❑ 8 Nm
du
an
itte
y li
erm
3 - Nut
ab
ility
ot p
❑ 8 Nm
wit
, is n
h re
4 - Bracket
hole
❑ for actuator for struc‐ spec

es, in part or in w
ture-borne sound -
t to the co
R214-
5 - Nut
rrectness of i
❑ 15 Nm
l purpos
6 - Bolts
❑ 8 Nm
nf
ercia
orm
7 - Bolt
m
atio
m
❑ 8 Nm
o
n in
or c
thi
e
8 - Actuator for structure-borne

t
sd
iva
sound - R214-
o
r
rp
cu
o
❑ Fitting location: in ple‐

f
en
ng
t.
yi
num chamber
Co
Cop py
t.
❑ To remove and install,
rig
gh ht
yri by
plenum chamber cover op Vo
by c lksw
and plenum chamber bulkhead must be removed. cted agen
Prote AG.
9 - Bracket
❑ for control unit for structure-borne sound - J869-
10 - Nuts
❑ 8 Nm
5. Senders and sensors 165

Scirocco 2015 ➤
5.2 Removing and installing air mass meter

- G70- AG. Volkswagen
agen AG do
ksw es n
Removing y Vol ot g
ua
b
ed ran
– Separate connector -2-. thoris tee
or
au ac
– Release clips -arrows-. ss
ce
le
un
pt
– Unscrew bolts for air mass meter - G70- .
an
d
itte
y li
rm
– Remove air mass meter - G70- from air filter housing -1-.
ab
pe
ility
ot
Installing
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
If the air filter element is very dirty or wet, dirt or water could reach
the air mass meter - G70- and affect the air mass value. This
l purpos
would lead to loss of power, since a smaller injection quantity is

calculated.
nform
ercia
– Check air mass meter and intake hose (engine intake side) for
m
a
salt residue, soiling and leaves.
com
tion in
r
– Check intake port for dirt as far as the air filter element. If con‐
te o
thi
tamination is found, remove salt residues, dirt and leaves from
s
iva
do
r
top and bottom part of air filter housing by rinsing out or using
rp
cum
fo
a vacuum cleaner if necessary.
en
ng
t.
yi Co
op
– Note installation position of seal ⇒ page 155 . C py
t. rig
gh ht
yri by
Specified torques op Vo
by c lksw
cted agen
Prote
AG.
5.3 Removing and installing fuel pressure

sender - G247-

Scirocco 2015 ➤
AG. Volkswagen AG d
4-cylinder injection engine (2.0 l engine, turbocharger) swagen
Volkswagen R GmbH - oEdition
es n 09.2019
olk o t gu
V
by ara
ed
♦ Double hex socket 1/2”, 27mm - VAS 5301/7- horis nte
eo
t
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
WARNING
nform
mercia
a
Observe safety precautions when releasing fuel pressure in
com
tion in
the high-pressure system ⇒ page 145
r
te o
thi
s
iva
do
r

rp
cum
fo
en
ng
t.
yi Co
op py
nection. t. C rig
gh ht
pyri by
For reasons of safety, before opening the fuel system, remove
co Vo
by lksw
cted
fuse for the fuel pump control unit - J538- from the fuse holder.
agen
Prote AG.
This prevents the fuel pump from being activated by driver door
contact switch. Fuse assignment ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
– Detach coolant pipe and oil dipstick tube from intake manifold
-arrows-.
– Pull dipstick guide in direction of -arrow- upwards off engine.

– Using assembly tool - T10118- , release connector from fuel
pressure sender - G247- .
– Unscrew fuel pressure sender - G247- using double hexagon
socket Unscrew double hexagon socket, 1/2", 27 mm - VAS
5301/7- .
Installing
Specified torques
5.4 Checking fuel pressure sender - G247-

5. Senders and sensors 167

Scirocco 2015 ➤
♦ Pressure sensor tester - VAS 6394-
♦ Test adapter - VAS 5570-

Procedure
AG. Volkswagen AG d
agen
– Remove fuel pressure sender - G247- ⇒ page 166 . Volksw
oes
not
by gu
d ara
– Unscrew plug -2-. orise nte
eo
th
u ra
– Screw fuel pressure sender - G247- into testerss-a VAS 6394/1- . c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Moisten tapered seal of adapter - VAS 6294/2- with clean en‐
l purpos
gine oil and screw into fuel rail.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Scirocco 2015 ➤
– Connect pressure line of tester - VAS 6394/1- to adapter - VAS

6394/2- .
– Connect fuel pressure sender -1- and electrical connector of
fuel pressure sender using test instrument adapter - VAS
5570- .
– Reinstall air filter housing, and connect air mass meter - G70- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
169
by lksw
cted agen
Prote 5. Senders and sensors
AG.
Scirocco 2015 ➤
– Switch tester - VAS 6394/1- on. Press button -A- once briefly
for this.
Note
♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the tester - VAS 6394/1- reading is not 0 bar, carry out zero
calibration procedure ⇒ Operating instructions .
– Connect ⇒ Vehicle diagnostic tester to diagnostic connector.

– Switch on ignition.
– One after other, press following buttons on display of ⇒ Vehicle
diagnostic tester:
Vehicle self-diagnosis
Self-diagnosis ►
01 - Engine electronics ►
011 - Measured values ►
– Select measured value block 1 4 0 and acknowledge with

Q.
The actual fuel pressure value is shown in display zone 3, meas‐

ured by the fuel pressure sender - G247- .
– Start engine.
– Compare pressure displayed on tester - VAS 6394/1- with ac‐
tual value displayed on vehicle diagnostic tester .
• A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, renew fuel pressure
sender - G247- . wage
e ks s no
Vol t gu
d by ara
e
WARNING
tho
ris nte
eo
au ra
ss c
The tester - VAS 6394- is under extreme fuel pressure! With
ce
e
nl
engine running, pull electrical connector off fuel pressure send‐

pt
du
an
itte
er - G247- . This reduces fuel pressure to approx. 6 bar. Switch

y li
erm
ab
off ignition. Place a cleaning cloth around the fuel pressure

ility
ot p
sender - G247- , then reduce residual pressure by carefully

wit
loosening the fuel pressure sender - G247- .

, is n
h re
hole
spec
es, in part or in w
– Repeat the test with the new fuel pressure sender - G247- and
t to the co
compare both measured values.

If measured values again fail to correspond:
rrectness of i
– Perform line test ⇒ Vehicle diagnostic tester.

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
170
Prote AG.
Rep. gr.24 - Mixture preparation - injection
Scirocco 2015 ➤
6 Engine (motor) control unit

⇒ “6.1 Removing and installing engine (motor) control unit J623
”, page 171
6.1 Removing and installing engine (motor)

control
lksw
agenunit - J623-
AG. Volkswagen AG d
oes
n
o ot g
yV u
⇒ “6.1.1 Removing
ed
b and installing engine (motor)acontrol
ran unit J623
ris
”, page
utho171 tee
o ra
sa c
⇒ “6.1.2
s Removing and installing engine (motor) control unit J623
ce
e
with protective housing”, page 172

nl
pt
du
an
itte
y li
6.1.1 Removing and installing engine (motor)
erm
ab
ility
control unit - J623-
ot p
wit
, is n
h re
hole
spec
es, in part or in w
♦ Vehicle diagnostic tester
t to the co
Removing
– Switch on ignition, and select following menu options on⇒ Ve‐
rrectness of i
hicle diagnostic tester:
l purpos
♦ 01 - Engine electronics
♦ Guided Functions
nform
ercia
♦ 01 - Renew engine control unit

m
at
om
ion
c

in t
or
his
ate
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.

do
priv
gr. 92 ; Windscreen wiper system; Removing and installing

um
for
windscreen wiper arms .

en
ng
t.
yi Co
op py
t. C rig
gh ht
yri
p by
o Vo
num chamber bulkhead . by c lksw
cted agen
Prote AG.
– Press retaining frame downwards in direction of -arrow-.
– Remove engine control unit - J623- .
6. Engine (motor) control unit 171

Scirocco 2015 ➤
– Push catches in direction of -arrow-.

– Disconnect electrical connectors:
Installing
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
♦ Guided Functions AG. Volkswagen AG d
agen oes
ksw
♦ 01 - Renew engine control unit by V ol not
gu
ara
ed
ris nte
ho eo
ut
6.1.2 Removing and installing engine (motor)
ss a ra
c
control unit - J623- with protective hous‐
ce
le
un
pt
an
d
ing
itte
y li
rm
ab
pe
ility
ot
wit
, is n
♦ Vehicle diagnostic tester
h re
hole
spec
Removing
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tio
– Remove windscreen wiper arms: ⇒ Electrical system; Rep.

n in
r
gr. 92 ; Windscreen wiper system; Removing and installing

te o
thi
s
windscreen wiper arms .

iva
do
r
rp
cum

fo
en
ng

t.
yi Co
op
num chamber bulkhead . C py
t. rig
gh ht
yri by
– Press retaining frame downwards in direction of -arrow-.
op Vo
by c lksw
cted agen
Prote
– Remove engine control unit - J623- .
AG.

n AG. Volkswagen AG do Scirocco 2015 ➤
wage e
4-cylinder injection engine (2.0 l engine, y Vo turbocharger) Volkswagens nR
lks ot GmbH
gu - Edition 09.2019
db ara
ir se nte
– Unscrew shear-head bolts -arrows- ut using a pair of pliers.
ho eo
ra
a c
ss
– Remove locking bracket.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Push catches in direction of -arrow-.
l purpos
– Disconnect electrical connectors:
nform
ercia
Installing
m
a
com
t
ion in
r
te o
– Evenly tighten shear bolts until bolt heads shear off.
thi
s
iva
do
After a new engine (motor) control unit has been installed, the
r
rp
cum
fo
following work procedure must be carried out:
en
ng
t.
yi Co
op
– Switch on ignition, and select following menu options on⇒ Ve‐ C py
t. rig
hicle diagnostic tester: gh ht
pyri by
Vo
co lksw
by
♦ 01 - Engine electronics Prote
cted AG.
agen
6. Engine (motor) control unit 173

Scirocco 2015 ➤
7 High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 174
⇒ “7.2 Removing and installing high-pressure pump”, page 175
7.1 Assembly overview - high-pressure pump
1 - Plunger
2 - O-ring
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
3 - High-pressure pump with
fuel pressure regulating valve -
N276-
⇒ page 175
4 - Bolts
❑ 10 Nm
5 - Union nut
❑ When loosening, coun‐
terhold threaded con‐
nection
❑ Before installing, check
torque of threaded con‐
nection in high-pressure
pump
❑ Install fuel pipe free of agen
AG. Volkswagen AG d
oes
tension. olksw not
byV gu
ara
❑ 27 Nm rised
nte
ho eo
ut
6 - High-pressure pipe ss a ra
c
❑ Observe safety precau‐
ce
le
un
pt
tions when releasing

an
d
itte
y li
fuel pressure in high-

erm
ab
pressure system
ility
ot p
⇒ page 145
wit
is n
h re
ole,
spec
❑ Only renew if loosened.

t to the co
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
a »grip edge«.
rrectne
❑ 30 Nm
s
8 - Low pressure fuel hose

s o
cial p
❑ Secure with spring-type clip.

inform
mer
9 - Banjo bolt with conical sealing seat

atio
m

o
n
c
i
or
❑ Install fuel pipe free of tension.

thi
te
sd
va
❑ When loosening, counterhold threaded connection

i
o
pr
cum
r
fo
❑ 15 Nm
en
ng
t.
yi Co
op
10 - Fuel line C py
ht. rig
rig ht
❑ Low pressure py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor eo Scirocco 2015 ➤
u ra
4-cylinder injection engine
ss a (2.0 l engine, turbocharger) Volkswagen R GmbH c - Edition 09.2019
ce
e
nl
pt
du
an
itte
y li
❑ Only renew if loosened.
erm
ab
ility
ot p
❑ Always leave old seal in high-pressure pump when renewing threaded connection. When initially installed
wit
, is n
at the factory, it is crushed and cannot be removed. To seal, the new threaded connection is fitted with
h re
a »grip edge«.
hole
spec
❑ 30 Nm es, in part or in w
t to the co
12 - Threaded connection for high-pressure pipe
❑ Do not loosen threaded connection, only retighten
rrectness of i
❑ 40 Nm
l purpos
13 - Fuel pressure sender for low-pressure - G410-

❑ 15 Nm
nform
ercia
14 - Seal
m
at
om
ion
c
in t
or
his
ate
do
riv
7.2 Removing and installing high-pressure

p
cum
for
en
g
pump
n
t.
yi Co
Cop py
t. rig
Removing
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
Observe safety precautions when releasing fuel pressure in

the high-pressure system ⇒ page 145
nection.
For reasons of safety, before opening the fuel system, remove
fuse for the fuel pump control unit - J538- from the fuse holder.
This prevents the fuel pump from being activated by driver door
contact switch. Fuse assignment ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
Note
♦ Never dismantle the high-pressure pump.

♦ Observe rules for cleanliness ⇒ page 4 .

– Set engine to TDC.
7. High-pressure pump 175

Scirocco 2015 ➤
– Disconnect electrical connectors -1 and 2-.
Connections of old high-pressure pumps:

Connections of new high-pressure pumps:

– Pull off fuel hose.
AG. Volkswagen A
– Unscrew union nut -3- counterholding lon connection
wagen -2- to do
G do
es n
o ks ot g
so. d by V ua
r e an
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Continuation for all versions:

h re
hole
spec

es, in part or in w
t to the co
– Carefully pull out high-pressure pump.

rrectness of i
Note
l purpos
Under certain circumstances, the plunger ⇒ Item 1 (page 174)

may become stuck in the cylinder head.
nform
ercia
Installing
m
at
om
ion
c

in t
or
his
te
– Renew high-pressure pump O-ring and coat slightly with clean

a
do
riv
engine oil.
p
cum
for
en
ng
t.
– Check plunger ⇒ Item 1 (page 174) for damage and insert cyl‐ op
yi Co
inder head.
C py
ht. rig
rig ht
py by
Specified torques co Vo
by lksw
cted agen
Prote AG.
♦ ⇒ “7.1 Assembly overview - high-pressure pump”, page 174

Scirocco 2015 ➤
26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 177
⇒ “1.2 Removing and installing front exhaust pipe”, page 179
⇒ “1.3 Separating exhaust pipes from silencers”, page 180
⇒ “1.4 Aligning exhaust system free of stress”, page 181
⇒ “1.5 Installation position of clamp”, page 182
⇒ “1.6 Checking exhaust system for leaks”, page 182
⇒ “1.7 Checking exhaust flap”, page 183
1.1 Assembly overview - silencers
1 - Nuts
❑ 40 Nm
2 - Front exhaust pipe with cat‐
alytic converters
Caution
Risk of damage to flexi‐
ble joint.
Do
♦ not allow the flexible
joint to kink by more than
10°.
Install
♦ flexible joint so that
it is not under tension.
Do
♦ not damage wire n AG. Volkswagen AG do
swage es n
mesh on decoupling ele‐ byV
olk ot g
ua
ment. ir se
d ran
tee
tho
u or
a ac
❑ Protect catalytic con‐ ss
ce
e
verter from damage by

nl
pt
du
an
knocks and impact

itte
y li
erm
ab

ility
ot p
⇒ page 179
wit
, is n
❑ Aligning exhaust sys‐

h re
hole
tem free of tension

spec
⇒ page 181 .
es, in part or in w
t to the co
3 - Lambda probe after catalyt‐

ic converter - G130-
❑ Grease only the thread
rrectness of i
with high-temperature
l purpos
paste - G 052 112 A3- .

Do not allow the paste to
penetrate into the slots
nf
ercia
on the probe body.

orm
m
atio
❑ 55 Nm
om
n in
c
4 - Clamping sleeve
or
thi
te
sd
a
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 181
iv
o
r
rp
cu

o
m
f
en
ng
t.
yi
❑ Tighten bolted connections evenly.
Co
Cop py
t. rig
gh ht
pyri by
177
co Vo
by lksw
cted 1. Exhaust pipes and silencers
agen
Prote AG.
Scirocco 2015 ➤
5 - Centre silencer
❑ Centre and rear silencers are one unit as original equipment, but can be renewed separately for repair
purposes.
❑ Aligning exhaust system free of tension ⇒ page 181 .
❑ Separate exhaust system ⇒ page 180
6 - Bracket
❑ Riveted onto heat shield
7 - Bolt
❑ 23 Nm
8 - Retainer
9 - Rear silencer
❑ Rear silencer and centre silencer are one unit as original equipment, but can be renewed separately for
repair purposes.
❑ Aligning exhaust system free of tension ⇒ page 181 .
❑ Separate exhaust system ⇒ page 180
10 - Mounting
11 - Bolt
❑ 23 Nm
12 - Vacuum actuator
13 - Vacuum hose
❑ To vacuum unit
❑ Individual parts of vacuum unit ⇒ page 178
14 - Nut AG. Volkswagen AG d
agen oes
❑ 23 Nm olksw not
V gu
d by ara
e nte
15 - Bolt horis
eo
ut ra
❑ 23 Nm ss a c
ce
e
nl
16 - Mounting
pt
du
an
itte
y li
17 - Seal
erm
ab
ility
ot p

wit
, is n
h re
18 - Lambda probe - G39-

hole
spec
❑ Grease only the thread with high-temperature paste - G 052 112 A3- . Do not allow the paste to penetrate
es, in part or in w
into the slots on the probe body.

t to the co
❑ 55 Nm
rrectness of i
Individual parts of vacuum unit

l purpos
1 - To exhaust flap vacuum unit ⇒ Item 12 (page 178)

nf
ercia
2 - Exhaust flap valve - N321-

orm
m
atio
3 - Bracket
om
n in
or c
4 - Vacuum reservoir
thi
te
sd
iva
5 - Coupling point (line to intake manifold)

o
r
rp
cu
o
m
f
en
ng
Installation location of vacuum unit: in wheel housing at rear left

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
178 Rep. gr.26 - Exhaust system

Scirocco 2015 ➤
1.2 Removing and installing front exhaust

pipe
Removing
– Disconnect connector for lambda probe - G39- -arrow-.
– Unscrew front exhaust pipe/turbocharger nuts -arrows-.

– Pull underbody cover down slightly. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Disconnect connector for lambda probe after catalytic con‐

t to the co
verter - G130- -arrow-.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
179
by lksw
cted agen
Prote 1. Exhaust pipes and silencers
AG.
Scirocco 2015 ➤
– Unscrew bolts -arrows-. AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove cross member.
rrectness of i
– Loosen clamp -1- and push to rear.
l purpos
Caution
nform
mercia
a
Danger of damage to the de-coupling elements.
com
tion in
♦ Do not bend de-coupling elements in front exhaust pipe
r
te o
thi
by more than 10°.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Detach front exhaust pipe with catalytic converter.
Co
Cop py
ht. rig
Installing rig ht
py by
co Vo
by lksw
Install in reverse order of removal, observing the following: cted agen
Prote AG.
Note
♦ Coat studs of turbocharger with high-temperature paste - G

052 112 A3- .
♦ Renew seals, gaskets and self-locking nuts.
Align exhaust system free of stress ⇒ page 181 .

Specified torques
1.3 Separating exhaust pipes from silencers

♦ Chain-type pipe cutter - VAS 6254-

Scirocco 2015 ➤
♦ or body saw - V.A.G 1523A-
Procedure
Note
♦ To allow for individual renewal of the centre and rear silencers,

the connecting pipe has a coupling point.
♦ The coupling point is marked with indentations on the outside
of the exhaust pipe.
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
– Cut through exhaust pipe at cutting point -arrow 2- using chain

pipe cutter - VAS 6254- or body saw - V.A.G 1523A- .
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– Centre clamp -4- on side marks wheny installing,
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– Install clamp so that bolt ends do not protrude beyond lower

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• Threaded connection faces to rear.
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– Aligning exhaust system free of tension ⇒ page 181 .

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1. Exhaust pipes and silencers 181

Scirocco 2015 ➤
Procedure
– Loosen bolts -3 and 4- on front clamp -1-.
– Align front clamp -1- to marking -A- on front exhaust pipe -2-
(-arrow- points forwards).
• Dimension -a- = 5 mm
• Do not allow the bolts must be on the right and the ends to
protrude beyond the lower edge of the clamp.
– Tighten front clamp bolts -3- hand-tight.
– Push exhaust system forward until preload on rear silencer

retainer is dimension -a- 15…17 mm.
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1.6 Checking exhaust system for leaks

– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.

Scirocco 2015 ➤
– Check (by listening) points of connection between exhaust

manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.
1.7 Checking exhaust flap

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• Vacuum pipes and hose connections free of leaks.
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• Vacuum hoses not blocked or porous.
– Pull hose off vacuum unit for exhaust flap -A-.
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– Connect hand operated vacuum pump - VAS 6213- to vacuum
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐ cop Vo
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1. Exhaust pipes and silencers 183

Scirocco 2015 ➤
– Use hand operated vacuum pump - VAS 6213- to generate

vacuum and observe linkage.
• Linkage of vacuum unit -1- must move backwards.
– Admit air to hand operated vacuum pump - VAS 6213- .
• Linkage must move forwards.
If the linkage does not move:
– Check linkage for freedom of movement and/or check vacuum
unit for leaks.
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Scirocco 2015 ➤
2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 185
⇒ “2.2 Removing and installing catalytic converter”, page 185
2.1 Assembly overview - emission control

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2. Emission control 185

Scirocco 2015 ➤
28 – Ignition system
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1 - Knock sensor 1 - G61-
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❑ To remove, the coolant
thermostat housing
must be removed
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⇒ page 116
❑ Gold-plated contacts
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❑ Remove and install with

spark plug socket and
extension - 3122 B-
❑ Type and electrode gap
⇒ page 188 .
❑ 25 Nm
5 - Bolt
❑ Specified torque influ‐
ences the function of the
knock sensor.
❑ 20 Nm
6 - Bolt
❑ 10 Nm
8 - O-ring

Engine speed sender - G28- 10 Nm
1.2 Removing and installing ignition coils

with output stage
186 Rep. gr.28 - Ignition system

Scirocco 2015 ➤
♦ Puller - T40039-
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♦ To pull off spark plugs, fit puller - T40039- onto uppermost,
thick rib -arrow- of ignition coils with output stage.
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♦ If the lower ribs are used, they could be damaged.
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– Pull all ignition coils out of spark plug recess using puller -
T40039- .
Installing
Installation is carried out in the reverse order. When installing,
note the following:
Note
♦ When fitting new spark plugs, the ignition coil must be re‐
greased using lubricating paste - G 052 141 A2- This will stop
the ignition coil sealing hose from sticking to the spark plug.
The lubricating paste must be distributed on the spark plug
when inserting on the ignition coil.
♦ New ignition coils with output stage are lubricated when de‐
livered.
♦ The lubricating paste coat must be 1…2 mm thick.
1. Ignition system 187

Scirocco 2015 ➤
– Apply a thin coat of lubricating paste - G 052 141 A2- around

the ignition coil sealing hose -arrow-.
1.3 Test data, spark plugs

Engine code CDLA and CDLC
Firing order 1-3-4-2
Spark plugs
VW/Audi ⇒ Electronic parts catalogue (ETKA)
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188 Rep. gr.28 - Ignition system

VW Scirocco 2008-2015 - 4-Cyl. Injection Engine (2.0l Engine, Turbocharger) VW R GMBH (CDLA CDLC CDLK)

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VW Scirocco 2008-2015 - 4-Cyl. Injection Engine (2.0l Engine, Turbocharger) VW R GMBH (CDLA CDLC CDLK)

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Service

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B80465DB3

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.5 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 117

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . at 166

5.4 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

6 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.1 Safety precautions when working on the cooling system

ning. Touching the ignition system may result in an electric shock.

– Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.

Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐

– Switch off the ignition before connecting or disconnecting elec‐

– Switch off the ignition before washing the engine.

1.3 Safety measures when working on fuel supply

Danger of fire caused by escaping fuel

Risk of injury due to unexpected motor start

If the vehicle’s start/stop system is activated, the engine can start

unexpectedly. A message in the dash panel insert indicates

Risk of injury caused by unsecured testing and measuring instru‐

When the front passenger airbag is triggered in an accident, in‐

sufficiently secured testing and measuring instruments become

– Have a second person operate the test and measuring equip‐

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Bore ∅ mm 82.5 82.5 82.5

Stroke mm 92.8 92.8 92.8

Compression ratio 9.8 9.8 9.8

Valves per cylinder 4 4 4