D4B8047B934-4-Cylinder Injection Engine (1 4 L 4V EA211 Turbocharger)

Service
Workshop Manual
Jetta 2015 ➤
4-cylinder injection engine (1.4 l, 4V, EA211,
turbocharger)
Engine ID
CZC CZD CZTA
A A
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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
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8047B934

Jetta 2015 ➤
4-cylinder injection engine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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s1.2 Separating engine and gearbox . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.7 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 37

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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.8 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Assembly overview - drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
Jetta 2015 ➤
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.6 Removing and installing oil spray jets . . .A.G.. V. o. lk.s.w.ag. e.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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15 - Cylinder head, valve gear . . .ed.by. . . . . . . . . . . . . . . . . . . . .t g.ua.ra. . . . . . . . . . . . . . . 78
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1 Cylinder head . . . . . . . .uth. o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e.or. . . . . . . . . . . . . . . 78
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1.1 Assembly overview - cylinder
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1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.1 Assembly overview - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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2.3 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.5 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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2.6 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

2.7 Removing toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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3.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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3.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.6 Removing and installing exhaust camshaft control valve 1 N318 . . . . . . . . . . . . . . . . . . . . 154
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3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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3.8 Removing and installing toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 179
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 189
4.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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Jetta 2015 ➤
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4.5 Removing and installing ris
oilthopressure regulating valve N428 .. . . . . . .te.e o. . . . . . . . . . . . . . . 191
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.2 Assembly overview - engine preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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1.4 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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1.5 Removing and installing engine preheating element Z97 . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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2.7 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 219
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2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 220

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2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 221
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3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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4.2 Assembly overview - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 231
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.6 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.7 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 245
1.4 Removing and installing connection for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.3 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.5 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Contents iii
Jetta 2015 ➤
3.3 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.2 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.3 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
6.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 285
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8 Lambda probe . . . . . . . . . . . . . . . . . . w. a. g.e.n A.G. ..V.o.lk.sw. a. g.e.n .AG. .do. e. . . . . . . . . . . . . . . . . . . . . . 296
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8.2 Removing and installing Lambda or
is probe . . . . . . . . . . . . . . . . . . . . . . . .an. te. . . . . . . . . . . . . . .
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26 - Exhaust system . . . . . . . s. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
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1.3 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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1.6 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
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2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

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1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

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1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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1.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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1.5 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
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iv Contents
Jetta 2015 ➤
00 – Technical data
1 Safety information
(VRL013299; Edition 07.2019)
⇒ “1.1 Safety measures when working on fuel supply”,
page 1
⇒ “1.2 Safety measures when working on vehicles with start/stop
system”, page 1
⇒ “1.3 Safety precautions when Vousing
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⇒ “1.4 Safetyriprecautions
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⇒ “1.5 Safety
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1.1 Safety measures when working on fuel supply
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Risk of injury from highly pressurised fuel.
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The fuel system is pressurised. Injury from fuel spray possible.
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Before opening the fuel system:

– Wear safety goggles. t to the co
– Wear protective gloves.

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– To release pressure, wrap a clean cloth around the connection

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and carefully loosen the connection.

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Danger of fire caused by escaping fuel

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– Disconnect voltage supply to fuel pump before opening the
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1.2 Safety measures when working on vehicles with start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
Jetta 2015 ➤
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1.4 Safety precautions when working on cooling system

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– Wear safety goggles.
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– Reduce excess pressure by covering the cap of the coolant
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expansion tank with cloths and opening carefully.
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1.5 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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– Switch off the ignition before connecting or disconnecting elec‐
tric cables.
– Switch off the ignition before washing the engine.
2 Rep. gr.00 - Technical data

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

The engine code and the engine number are located on the stick‐
er -arrow- on the upper toothed belt guard.
The engine code is also on the vehicle data sticker and on the
crankcase above the gearbox.
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.
Vehicles with four digit engine codes
Four-place engine codes are being introduced, starting with letter
“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit denotes
the performance and torque rating of the engine and depends on
the engine control unit - J623- . The four-digit engine code can be
found on the identification plate, the vehicle data
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Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;
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Vehicle data sticker .

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Engine code CZCA CZDA h re

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Exhaust emission standard EU6 EU6 ULEV2
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Displacement cm 3 1395 1395 1395

Power kW at 92/5000-6000 110/5000-6000 110/5000
rpm
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Torque Nm at 200/1400-4000 250/1500-3500 250/1400-3500

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Bore Diamet 74.5 74.5 74.5
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Stroke 80.0 mm
80.0 80.0
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Compression ratio 10.0 10.0 10.0

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Valves per cylinder 4 4 4

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RON min. 95 unleaded (in excep‐ 95 unleaded (in excep‐ 95 unleaded (in excep‐
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reduced performance) with reduced perform‐ reduced performance)
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Injection, ignition system Motronic ME 17 Motronic ME 17 Motronic ME 17
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2
2. Identification 3
Jetta 2015 ➤
3 Repair notes
⇒ “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
3.1 Rules for cleanliness

Risk of malfunction due to soiling
When working on the fuel supply and injection system, pay par‐
ticular attention to the following “7 rules” of cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover them over.
Use only lint-free cloths.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only: do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.
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When performing assembly ris work on the engine, all open passag‐ ante
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plugs to prevent foreign particles from entering the engine.
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Use e.g. plugs from engine bung set - VAS 6122- .

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3.3 Contact corrosion

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Contact corrosion can occur if unsuitable connecting elements

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(screws, bolts, nuts, washers, etc.) are used.

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For this reason, only connecting elements with a special surface

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coating have been fitted.

In addition, rubber, plastic and adhesives are made of non-con‐
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ductive materials.
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If there is any doubt about the suitability of parts, a general rule

is to use new parts ⇒ Electronic parts catalogue (ETKA) .
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3.4 Routing and attachment of lines

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♦ To rule out mix-ups and ensure that lines for fuel, hydraulics,
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vacuum, activated charcoal filter system and electrics are all

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installed in their original position, mark all such lines for iden‐
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tification before removing them.

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♦ If necessary, take a photo or make a sketch.

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Rep. gr.00 - Technical data
Jetta 2015 ➤
♦ To avoid damaging pipes and wires, ensure adequate clear‐

ance from all moving or hot components in the engine com‐
partment on account of the confined space.
3.5 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents.
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3. Repair notes 5
Jetta 2015 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 6
⇒ “1.2 Separating engine and gearbox”, page 16
⇒ “1.3 Securing engine on engine and gearbox support”,
page 18
⇒ “1.4 Installing engine”, page 19
1.1 Removing engine
Special tools and workshop

equipment required
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♦ Release lever - 80 - 200-

♦ Extension -2024 A /1- of lifting tackle - 2024 A-
♦ Engine and gearbox jack - V.A.G 1383 A- or -VAS 6931-
♦ Engine support - T10497-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
6 Rep. gr.10 - Removing and installing engine

Jetta 2015 ➤
♦ Locking pin - T10060 A-
♦ Commercially available stepladder

♦ Safety goggles
♦ Protective gloves
Procedure
– Reinstall all cable ties in the same locations when installing.
Note
The engine is removed downwards together with the gearbox.
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tee
Hot steam/hot
utho coolant can escape - risk of scalding. or
a ac
There sis
s
a risk of injury to the skin and parts of the body due to
ce
e
scalding.
nl
pt
du
an

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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
– Open filler cap -arrow- for coolant expansion tank.

t to the co
– Remove left and right front wheel ⇒ Running gear, axles,

steering; Rep. gr. 44 ; Wheels, tyres and alignment .
rrectness of i
– Remove noise insulation ⇒ General body repairs, exterior;

l purpos
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐

sulation .
nf
ercia
– Remove left and right front wheel housing liner ⇒ General

orm
body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; As‐

m
atio
m
sembly overview - front wheel housing liner .

o
n in
or c
thi
– Place drip tray for workshop hoist - VAS 6208- underneath.

te
sd
iva
o
r
– Disconnect connector -1- from radiator outlet coolant temper‐

rp
cu
o
ature sender - G83- -2-.

f
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
1. Removing and installing engine 7

Jetta 2015 ➤
– Lift securing clip -3-, and remove lower right coolant hose from
radiator.
– Drain coolant.
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rm
ab
pe
ility
– Lift securing clip -arrow-, and disconnect lower right coolant
ot
wit
hose from water radiator for charge air cooling circuit. , is n
h re
hole
– Allow remaining coolant to drain out.
spec
es, in part or in w
– If poly V-belt is to be reinstalled, mark direction of rotation on
t to the co
belt using chalk or felt tip pen before removing.
rrectness of i
l purpos
nform
mercia
a
com
tio
Vehicles with air conditioner compressor
n in
r
te o
thi
– To slacken poly V-belt, turn tensioning element anti-clockwise
s
iva
do
-direction of arrow-.
r
rp
cum
fo
en
g
– Remove poly V-belt from poly V-belt pulley on air conditioner

n
t.
yi Co
op
compressor. C py
t. rig
gh ht
yri
– Use the locking pin - T10060 A- to lock the tensioner.
p by
o Vo
by c lksw
cted agen
– Remove poly V-belt.
Prote AG.
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
– Separate connector -1- on air conditioning compressor regu‐

lating valve - N280- .
– Unscrew bolts -arrows- for air conditioning compressor.
Note
Do NOT stretch, kink or bend refrigerant lines and hoses.
– Remove air conditioner compressor with refrigerant lines con‐

nected and tie it up on the right side.

Jetta 2015 ➤
Continued for all vehicles

– Lift retaining clip -arrow-, and remove upper left coolant hose
from radiator.
– Lift retaining clip -arrow-, and remove upper right coolant hose
from water radiator for charge air cooling circuit.
– Remove radiator cowl ⇒ page 233 .
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ility
ot p
wit
is n
– Attach protective mat - VAS 531003- to vehicle as shown in
h re
illustration.
ole,
spec
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

t to the co
Disconnecting and connecting battery .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
rrectne
27 ; Battery; Removing and installing battery tray .

ss o
cial p
f inform
mer
atio
om
n
c
i
or
– Release catch -arrow- and disconnect vacuum hose -1-.

thi
te
sd
iva
o
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– Move clear vacuum hose at air pipe -2-.

p
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.

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Jetta 2015 ➤ ut
ho eo
ra
a
4-cylinder injection engine (1.4 l, 4V, EA211, turbocharger)
ss - Edition 07.2019 c
ce
le
un
pt
– Lift securing clips in direction of -arrow-. Disconnect coolant
an
d
itte
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hoses -1- and -2- from heat exchanger for heater.
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
ercia
Vehicles with auxiliary heater
m
a
– Release retaining clip and hose clip, and pull off both coolant
com
tion in
hoses -arrows-.
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.

– Unscrew bolt -2- and remove screw-type clip.
– Remove bolt -1- and nuts -arrows- and tie up catalytic con‐
verter.
– Undo bolts -arrow- and remove bracket.

– Place a cloth underneath to catch any escaping coolant.

Jetta 2015 ➤
– Release hose clip -1- and pull off coolant hose.
– Disconnect hose couplings -1- and -2-.

– Remove air filter housing ⇒ page 271 .
lkswage es n
o ot g
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tho
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a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
– For the work steps below use removal lever - 80 - 200- to unclip
hole
spec
the binding clips.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– Detach battery positive cables -1- from electronics box -2- by

t
sd
iva
loosening nuts -arrows-.

r
rp
cu
o
m
f
en
ng
– Pull off connecting pipe -1-. To do this, press retaining ring

t.
yi Co
op
together on both sides. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
– Unscrew earth connection -2- and provide access to cable

duct -1-.
lkswage es n
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tho
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ss
ce
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nl
pt
du
an
itte
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erm
ab
– Release and pull off connectors -3-.
ility
ot p
wit
– Open catches -arrows- of cable duct -1-.
, is n
h re
hole
– Place wiring harness on engine.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Release and pull off connector -arrows-.

om
n in
or c
– Unclip wiring harness from bracket -1-.

thi
te
sd
iva
Manual gearbox
o
r
rp
cu
o
m
f
en
ng
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;

t.
yi Co
Selector mechanism; Removing and installing selector mech‐ Cop py
. rig
anism .
t
gh ht
pyri by
Vo
co
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐
by lksw
cted agen
Prote
nism; Removing and installing clutch slave cylinder .
AG.
Automatic gearbox
– Remove selector lever cable, pull off mechatronics connector
and remove all retainers from gearbox ⇒ Rep. gr. 34 ; Re‐
moving and installing gearbox

– Pull off breather line -arrow-.
– Release locking lug -3- in -direction of arrow-, and remove ac‐
tivated charcoal filter -1- upwards.
– Place activated charcoal filter -1- on engine with line -2- con‐
nected.

Jetta 2015 ➤
– Unscrew bolt -4- and turn filler neck for washer fluid reservoir
-2- towards front.
– Open clip -3-, and pull connector -5- off coolant expansion tank
-1-.
– Unscrew bolts -arrows-, and place coolant expansion tank
-1- with hoses connected on engine.
– Unscrew bolts -1- from engine mounting -2- approx. 2 turns.
AG. Volkswagen AG d
agen oes
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d by ara
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h
aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
– Unscrew bolts -2- from gearbox mounting -1- by 2 turns.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Disconnect electrical connector -1- on oil level and oil temper‐

p
cum
ature sender - G266- .

for
en
ng
t.
yi
– Detach wire from retainer -2-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Unscrew nuts for coupling rod -arrow- on left and right of anti-
roll bar.
– Unscrew bolts -1, 2, 3-, and remove pendulum support.
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un
pt
an
d
itte
y li
– Unscrew bolts -arrows- and remove heat shield for right drive
erm
ab
shaft.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Unscrew nuts -arrows- for swivel joint on left and right.

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.

Jetta 2015 ➤
– If fitted, remove nut -arrow- from front left vehicle level sender
- G78- .
– Detach swivel joint from transverse link on left and right.
– Unscrew drive shaft on both sides from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Assembly
overview - Drive shaft and tie up.
Note
Take care not to damage the surface protection of the drive shaft.
– Swivel front left suspension strut outwards and support with

extension -2024 A /1- , as shown in illustration.
– Secure locking pin and swivel joint with locating pin -arrow-
and nut -1-.
– Secure swivel joint -2- (right-side) to transverse link -1- with

nut -arrow-, as shown in illustration.
– Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration.
AG. Volkswagen AG d
agen oes
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ara
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nl
pt
– Position engine support T10497 with pin T10497/1 on cylinder

du
an
itte
block.
y li
erm
ab
ility
– Screw in bolt -1- through hole “B” in engine support - T10497-

ot p
and tighten to 20 Nm.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
15
by lksw
cted agen
Prote 1. Removing and installing engine
AG.
Jetta 2015 ➤
– Fit adapter - T10497/3- to engine support - T10497- and tight‐

en bolt -1- to 20 Nm.
– Insert engine and gearbox jack - V.A.G 1383 A- in engine sup‐
port - T10497- and raise engine/gearbox assembly slightly.
– To unscrew bolts for assembly mounting use commercially
available stepladder.
– Remove bolts -1- for engine mounting -2-.
AG. Volkswagen AG d
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– Unscrew bolts -2-. ed byV gu
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Note s
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un
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an
d
itte
♦ Danger of damage to vacuum lines or electrical wiring and to

y li
erm
ab
engine compartment.
ility
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♦ Check that all vacuum lines and electrical wiring between en‐
wit
is n
h re
gine, gearbox, subframe and body have been detached.

ole,
spec
♦ When lowering, carefully guide engine/gearbox assembly with

assembly carrier out of engine compartment.
t to the co
♦ Depending on the gearbox, 2 or 3 bolts can be mounted.

rrectne
– First lower engine/gearbox assembly slightly.

s
– Then push gearbox end of engine/gearbox assembly forwards

s o
cial p
and only then lower further.

f inform
mer
1.2 Separating engine and gearbox

atio
om
n
c
i
or
Special tools and workshop equipment required

thi
te
sd
va
♦ Shackle - 10 - 222 A /12-

i
o
pr
cum
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fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
♦ Hook - 10 - 222 A /2-
♦ Workshop hoist - VAS 6100-
Procedure
G. Volkswagen
• Engine/gearboxlkassembly
wage
n A removed A
and
G doattached to engine
es n
Vo s .
bracket - T10497- ot g
by d ua
ran
ise t
– Removeut
ho starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
r ee
or
Removing
ss a and installing starter . ac
ce
e
– Bolt shackle - 10 - 222 A /12- to gearbox.

nl
pt
du
an
itte
y li
– Attach workshop hoist - VAS 6100- with hook - 10 - 222 A /2-

erm
ab
to shackle - 10 - 222 A /12- .

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.

orm
m
atio
– Pull gearbox off engine.

om
n in
or c
thi
te
sd
iva
o
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rp
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
1.3 Securing engine on engine and gearbox

support
♦ Engine and gearbox support - VAS 6095-
AG. Volkswagen AG d
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d by ara
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ility
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♦ Workshop hoist - VAS 6100-
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
a
Procedure
iv
o
pr
cum
r
fo
• Gearbox detached from engine ⇒ page 16 .
en
ng
t.
yi Co
op
– Secure lifting tackle - 2024 A- on engine, and attach it to work‐ C py
t. rig
shop hoist - VAS 6100- as shown in illustration.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ In order to match the lifting tackle to the centre of gravity of the

engine, the holes in the hook rail must be allocated as shown
in the illustration.
♦ The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Using workshop hoist - VAS 6100- , lift engine off engine

bracket - T10497- .

Jetta 2015 ➤
– Secure engine to engine and gearbox bracket - VAS 6095-

using pins -arrows- as shown in illustration.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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ab
1.4 Installing engine
ility
ot p
wit
is n
Procedure
h re
ole,
spec
• Engine/gearbox assembly secured to engine bracket -
T10497- .
t to the co
– Renew bolts that are tightened with turning further angle.
rrectne
– Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
s
– Engage all hose clips (same as original equipment) ⇒ Elec‐
s o
cial p
f
tronic parts catalogue (ETKA) .
inform
mer
– Fit all cable ties in the original position when installing.
atio
m
– Install intermediate plate ⇒ page 56 .

o
n
c
i
or
n thi
e
– If there are no dowel sleeves -A- in the cylinder block for cen‐
t
sd
va
tring the engine and gearbox, insert new dowel sleeves.

i
o
pr
cum
r
fo
en
– Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
ng
t.
yi Co
op py
– Install gearbox support. t. C rig
gh ht
pyri by
– Take up engine/gearbox assembly with engine support -
o Vo
by c lksw
cted agen
T10497- . Prote AG.
– Guide engine/gearbox assembly into body.
– First, screw in bolts -1- for engine mounting -2- to stop by hand.

Jetta 2015 ➤
– Initially in screw bolts -2- for gearbox mounting to stop by hand.
Note
The bolts are tightened to their final torque only after the assembly
mountings have been adjusted.
– Remove engine bracket - T10497- from engine.

– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; As‐
sembly overview - starter .
– Install air pipe ⇒ page 251 .
– Installing air ducts ⇒ page 253 .
Vehicles with manual gearbox
– Install clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mechanism;
Removing and installing clutch slave cylinder .
– Install cables with cable support bracket ⇒wagRep.
en AGgr.
. Volk34
swa;gSe‐
en AG
does
lector mechanism; Assembly overview yV
o-
lksselector cables . not
gu b ara
ed
Vehicles with an automatic gearbox
tho
ris nte
e or
au ac
– Install selector lever cable, sfit
s mechatronics connector and in‐
ce
stall all retainers on gearbox:⇒ Rep. gr. 34 ; Removing and
e
nl
pt
du
installing gearbox
an
itte
y li
erm
ab
ility
ot p
wit
– Install catalytic converter ⇒ page 310 .
, is n
h re
hole
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
spec
40 ; Drive shaft; Assembly overview - drive shaft .
es, in part or in w
t to the co
– Install transverse link, swivel joint and coupling rod ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower transverse link,
swivel joint; Assembly overview - lower transverse link, swivel
rrectness of i
joint .
l purpos
– Install air conditioner compressor ⇒ Heating, air conditioning;

Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
nf
ercia
orm
m
– Install poly V-belt ⇒ page 43 .

atio
om
n in
c
– Re-establish electrical connections, and route wiring ⇒ Elec‐

or
thi
trical system; Rep. gr. 97 ; Relay carriers, fuse carriers,

te
sd
iva
electronics boxes; Overview of fitting locations - relay carriers,

o
r
rp
cu
fuse carriers, electronics boxes and ⇒ Current flow diagrams,

o
m
f
en
ng
Electrical fault finding and Fitting locations.

t.
yi Co
Cop py
– Install engine control unit - J623- ⇒ page 285 .
t. rig
gh ht
pyri by
Vo
o
– Connect coolant hoses with plug-in connector ⇒ page 228 . by c lksw
cted agen
Prote AG.
– Install pendulum support ⇒ page 27 .
– Install left and right front wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Assembly
overview - front wheel housing liner .
– Install front wheels ⇒ Running gear, axles, steering; Rep. gr.
44 ; Wheels, tyres; Changing wheel .
– Adjust assembly mountings ⇒ page 35 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Install air filter housing ⇒ page 271 .

Jetta 2015 ➤
Note
♦ Never use battery charging equipment for boost starting.

♦ Danger of destroying control units through excessive voltage.
♦ Drained-off coolant may only be used again if the cylinder
head and cylinder block have not been renewed.
♦ Soiled coolant must not be reused.
♦ The specified torques are only valid for nuts and bolts which
have been slightly greased, oiled, phosphate-treated or black-
oxided.
♦ Additional lubricant such as engine oil or gear oil may be used,
but do not use lubricant containing graphite.
♦ Do not use degreased parts.
– Add coolant ⇒ page 199 .

– Connect ⇒ Vehicle diagnostic tester.
– After renewing engine, the misfiring adaptation function must
be performed. To do this, select function 01 - Reset mis-
firing adaptation in Guided Functions mode.
Torque settings agen

AG. Volkswagen AG d
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V
Componented by gu
ara Nm
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Bolts and
aut nuts
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M7 15
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un
pt
M8 20
an
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itte
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rm
M10 40
ab
pe
ility
M12 65
ot
wit
, is n
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 22

hole
spec
es, in part or in w
♦ Removing and installing gearbox; Installing gearbox ⇒ Rep.

t to the co
gr. 34 ; Removing and installing gearbox; Installing gearbox .

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 22
⇒ “2.2 Removing and installing engine mounting”, page 24
⇒ “2.3 Removing and installing gearbox mounting”, page 25
⇒ “2.4 Removing and installing pendulum support”, page 27
⇒ “2.5 Supporting engine in installation position”, page 27
⇒ “2.6 Adjusting assembly mountings”, page 35
⇒ “2.7 Checking adjustment of assembly mountings (engine and
gearbox mountings)”, page 37
2.1 Assembly overview - assembly mountings
1 - Connection AG. Volkswagen AG d

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2 - Bolt olksw not
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d
❑ Connection to engine orise nte
eo
mounting and body aut
h
ra
ss c
❑ Renew after removal
ce
e
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pt
du
❑ 20 Nm +90°
an
itte
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erm
ab
3 - Bolt
ility
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❑ Connection to engine
wit
, is n
mounting and body
h re
hole
spec
es, in part or in w
❑ 20 Nm +90°
t to the co
4 - Bolts
❑ Engine mounting to en‐
rrectness of i
gine support
l purpos

❑ 60 Nm +90°
nf
ercia
5 - Bolt orm
m
atio
❑ For bracket for activated

om
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charcoal filter
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thi
e

t
sd
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❑ 20 Nm +90°
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en
ng
t.
6 - Centre hex stud
yi Co
Cop py
❑ Engine mounting to ht. rig
rig ht
body
py by
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cted
agen
Prote AG.
❑ 40 Nm +90°
7 - Bolt
❑ Engine mounting to
body
❑ 40 Nm +90°
8 - Engine mounting
❑ Removing and installing ⇒ page 24
9 - Bracket
❑ For activated charcoal filter

Jetta 2015 ➤
10 - Bolt
❑ Engine support to engine
❑ Specified torque ⇒ page 24
11 - Engine support
12 - Bolt
❑ Gearbox mounting to gearbox support
❑ 60 Nm +90°
13 - Bolt
❑ Gearbox mounting to body
❑ 40 Nm +90°
14 - Gearbox mounting
❑ Illustration shows version for dual clutch gearbox.
15 - Bolt
❑ Gearbox support to gearbox
Specified torques:
❑ Vehicles with manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
gearbox
❑ Vehicles with automatic gearbox ⇒ Rep. gr. 37 ; Removing and installing gearbox; Specified torques
for gearbox
16 - Centre hex stud
❑ Gearbox support to gearbox
Specified torques: n AG. Volkswagen AG do
lkswage es n
❑ Vehicles with manual gearboxd byV
o
⇒ Rep. gr. 34 ; Removing ot g
uand
ara installing gearbox; Specified torques for
gearbox o
ir se nte
th eo
❑ Vehicles with automatic
au gearbox ⇒ Rep. gr. 37 ; Removing and rinstalling ac gearbox; Specified torques
ss
for gearbox
ce
le
un
pt
17 - Gearbox support
an
d
itte
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rm
ab
18 - Pendulum support
pe
ility
ot

wit
, is n
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❑ Bolt pendulum support to gearbox and then to subframe.

hole
spec
19 - Bolt
es, in part or in w
t to the co
❑ Pendulum support to subframe

rrectness of i

l purpos
20 - Bolts
❑ Pendulum support to gearbox
nform
ercia

m

a
com
tion in
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te o
thi
s
iva
do
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
2. Assembly mountings 23
Jetta 2015 ➤
Engine support - specified torques and tightening sequence

– Tighten bolts in stages in the sequence shown.
Stage Component Specified torques/angle specifications
1 Bolts -1 to 3- 7 Nm
3 Bolts -1 to 3- Turn 90° further
Pendulum support
• Renew bolts that are tightened with turning further angle.
Stage Component Specified torques/angle specifications
1 Bolts -2, 3- 50 Nm
2 Bolt -1- 130 Nm
3 Bolts -1 to 3- Turn 90° further gen AG. Volkswagen AG d
wa oes
olks not
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ris
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ss
2.2 Removing and installing engine mount‐
ce
e
nl
pt
du
ing
an
itte
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erm
ab

ility
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wit
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♦ Torque wrench - V.A.G 1331-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
♦ Socket - T40055-
at
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.

Jetta 2015 ➤
Removing
– Support engine in its installation position ⇒ page 27 .
– Release locking lug -3- in -direction of arrow-, and remove ac‐
nected.
-2- towards front.
-1-.
-1- on engine with coolant lines connected.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
– If fitted, unscrew jump-start connection
ised point -3- at front of en‐
b ara
nte
gine mounting -2- using socketut-h T40055- .
or eo
ra
s a c
s
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
rrectne
– Unscrew bolts -5- and remove bracket -4-.

– Unscrew bolts -1- and -3-, and remove engine mounting up‐
ss
wards.
o
cial p
f inform
Installing
mer
atio
Install in the reverse order of removal, observing the following:

om
n
c
i
or
– Checking adjustment of assembly mountings ⇒ page 35 .

thi
te
sd
va
Torque settings
i
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
2.3 Removing and installing gearbox cted agen
Prote AG.
mounting
Removing
– Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27 ;
Battery; Removing and installing battery tray .
Jetta 2015 ➤
– Remove engine control unit - J623- from bracket AG. Volkswagen AG d

⇒ page 285 . agen oes
olksw not
byV gu
ara
d
– Unclip wire guide -1- upwards -arrows-, and pushoitris slightly to
e nte
one side. aut
h eo
ra
ss c
ce
e
nl
pt
du
an
itte
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
orm
m
atio
om
n in
or c
– Unscrew bolts -2-. Then unscrew bolts -arrows-, and remove
thi
te
sd
a
gearbox mounting -1-.

iv
o
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m
Installing
f
en
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op
Install in the reverse order of removal, observing the following: C py
ht. rig
rig ht
Risk of damaging thread in gearbox support if bolts are started at
py by
co Vo
by lksw
an angle. Prote
cted AG.
agen
– Gearbox support and support arm of gearbox mounting must

be perfectly parallel to each other before screwing in bolts. If
necessary, lift gearbox at rear using trolley jack.
– Tighten gearbox mounting on longitudinal member.
– Lift gearbox with spindle of support bracket until gearbox sup‐
port makes contact with support arm of gearbox mounting.
– Checking adjustment of assembly mountings ⇒ page 37 .
– Remove support bracket - 10 - 222 A- from engine.
Torque settings
♦ ⇒ “2.6 Adjusting assembly mountings”, page 35
♦ ⇒ “6.1 Removing and installing engine (motor) control unit
J623 ”, page 285
♦ Assembly overview - battery ⇒ Electrical system; Rep. gr. 27 ;
Battery; Assembly overview - battery .

Jetta 2015 ➤
2.4 Removing and installing pendulum sup‐

port
Removing
– Remove noise insulation ⇒ oGeneral
lkswagen Abody repairs, exterior;
Rep. gr. 66 ; Noise en AG. V
waginsulation; Assembly
G do overview - noise in‐
es n
lks
sulation . d by Vo ot g
ua
e ran
ris t
– Unscrew
ut
ho bolts -1, 2, 3-, and remove pendulum support.
ee
or
sa ac
Installing
s
ce
le
un
pt
an
d
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
Note
♦ There are threaded inserts, e.g. “Heli-Coil” in the bolting holes
rrectness of i
for the pendulum support.
l purpos
♦ Identification: shoulder along beginning of thread -arrow-.
nform
ercia
Torque settings
m
a
♦ ⇒ Fig. ““Pendulum support”“ , page 24
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
2.5 Supporting engine in installation position

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
equipment required Prote
cted AG.
agen
♦ 2 x rotary joint - T40093/4- from engine support supplement

set - T40093-
Jetta 2015 ➤
♦ 2 x adapter - T40093/5- from engine support supplement set

- T40093-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
♦ 2 x square section tube - T40091/1- from engine support basic
h re
set - T40091-
ole,
spec
♦ 1 x hook rail - T40091/2- from engine support basic set -
t to the co
T40091-
♦ 2 x swivel joint - T40091/3- from engine support basic set -
T40091-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
♦ 1 x square section tube with both bolts from engine support

basic set - 10 - 222 A-
♦ 2 x spindle - 10 - 222 A 11- or spindle - 10 - 222 A 10- from
engine support basic set - 10 - 222 A-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
♦ 1 x adapters - 10 - 222 A /31 A-1-

r
rp
cum
fo
en
♦ 1 x adapters - 10 - 222 A /31 A-2-

ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
29
co Vo
by lksw
cted
2. Assembly mountings
agen
Prote AG.
Jetta 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
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
♦ 2 x adapters - 10 - 222 A /28-
rrectne
♦ 2 x adapters - 10 - 222 A /28-1-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
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
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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
op
♦ 2 x adapters - 10 - 222 A /20- C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Jetta 2015 ➤
Preparing tools
– If adapter -10 - 222 A - does not yet have the hole -arrow-, it
must now be drilled into it. AG. Volkswagen n AG do
wage es n
• olks
Dimension -a- = 225y Vmm. ot g
b ua
ed ran
• Hole diameterth=
or 12.5 mm.
is tee
or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Procedure
spec
es, in part or in w
– Detach exhaust system bracket from subframe -arrows-.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– First unscrew bolt -1-.

r
rp
cum
fo
en
g
– Then remove bolts -2- and -3-.

n
t.
yi Co
Cop py
– Remove pendulum support -4-.
t. rig
gh ht
pyri by
Vo
o
– Remove plenum chamber cover ⇒ General body repairs, ex‐
c by lksw
cted agen
terior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
Prote AG.
installing plenum chamber cover .

– Remove resonator for intake air ⇒ page 272 .
Note
The battery earth must be disconnected for the remaining proce‐

dure. Before doing so, check whether a coded radio is fitted in the
vehicle. Obtain anti-theft coding beforehand if necessary.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

27 ; Battery; Removing and installing battery tray .
– Release locking lug -3- in direction of arrow, and remove ac‐

Jetta 2015 ➤
olkswagen AG
en AG. V
– Place activated charcoal filter -1- on engine with kswline -2- con‐
ag does
not
Vol
nected. ed
by gu
ara
ris nte
– Unscrew bolt -4- and turn filler neckaufor
tho washer fluid reservoir eo
ra
-2- towards front. ss c
ce
e
nl
pt
du
an
itte
-1-.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Unscrew bolts -arrows- for retaining brackets on left and right
gh ht
pyri by
of lock carrier.
o Vo
by c lksw
cted agen
Prote AG.
– Unscrew lower supports from adapters - 10 - 222 A /28- and

replace them with adapters -10-222 A /28-1- .
– Unscrew bolts -arrows- for securing support bracket to lock
carrier from adapter - 10-222 A /28-1- .
– Use bolts from adapter -10-222 A /28-1- to attach adapters -
10 - 222 A /28- . Do not use securing bolts for brackets,
because they are too short.
Jetta 2015 ➤
– Fit adapter - 10 - 222 A /28- and tighten the bolts -arrows-.

Specified torque
Component Specified torque
Bolts -arrows- 8 Nm
Note
. Volkswage
A second mechanic is required for fitting
ksw
agthe support bracket
en AG n AG d
o-es10
- 222 A- to the vehicle to preventbythe
V support bracket from tippingot gu
ol n
ara
over. or
ised
nte
th eo
s au ra
c
s
ce
Fit support bracket as follows to support engine/gearbox assem‐
e
nl
pt
du
bly:
an
itte
y li
erm
ab
1- Adapter - 10 - 222 A /31-2-
ility
ot p
wit
2- Swivel joint - T40091/3-
, is n
h re
hole
3- Adapter - 10 - 222 A /31-1-
spec
es, in part or in w
t to the co
5- Square tube - T40091/1-
rrectness of i
6- Adapter - 10 - 222 A /28- with -10-222 A /28-2-
l purpos
– First push swivel joints -item 2- onto square tube - 10 - 222 A-

of support bracket .
nform
ercia
• Securing bolts securing swivel joints - T40091/3- -item 2- to

engine support bracket -10-222 A- must point in direction of
m
at
travel.
om
ion
c
in t
r
– Locate -10-222 A- on suspension turrets and have a second

o
his
e
mechanic hold it to prevent it from tipping over.

at
do
priv
cum
or
– Push -T40091/1- -item 5- on left and right from front through

f
en
g
-10-222 A /28- -item 6-.

n
t.
yi Co
Cop py
– Then, fit swivel joints - T40093/4- -item 4- on each side.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Push hook rail - T40091/2- -item 8- with supports - T40093/5-

-item 7- in swivel joints - T40093/4- -item 4-.
1- Adapter - 10 - 222 A /31-2-
3- Adapter - 10 - 222 A /31-1-
5- Square tube - T40091/1-
6- Adapter - 10 - 222 A /28- with -10-222 A /28-2-
7- Support - T40093/5-
8- Hook rail - T40091/2-
9- Spindle - 10 - 222 A /11-
10 - Hook - 10-222A/20-
– Insert locking pin in hole rail - T40091/2- -item 8- and secure
with split pins.
– Tighten all threaded connections of support bracket hand-
tight. When doing this, adjust support bracket via adapters -
10 - 222 A /28- so that it is horizontal.
– Take up weight of engine/gearbox assembly on spindles - 10
- 222 A /11- -item 9-, but do not lift.
lkswage es n
o ot g
2.6 Adjusting assembly mountings ir se
d byV ua
ran
o tee
h
Procedure aut or
ac
ss
ce
le
un
pt
an
d
itte
– Release locking lug -3- in direction of arrow, and remove ac‐
y li
rm
ab
pe
ility
ot
wit
, is n
h re
nected.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
-2- towards front.
nform
ercia
-1-.
m
a
com
tion in

r
te o

thi
s
iva
do
r
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

rp
cum
fo

en
ng
t.
yi Co
op
– Support engine with gearbox, but do not raise ⇒ page 27 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Jetta 2015 ➤
– Renew assembly mounting bolts -1, 3, and 5- in succession (if

not already carried out on installing engine) and screw them
in hand-tight.
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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Renew assembly mounting bolts -2- in succession (if not al‐
ready carried out on installing engine) and screw them in hand-
t to the co
tight.
– Tighten bolts of support arms on left and right only far enough
rrectne
that the bearings can still be moved.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
• There must be a distance of -a- at least 10 mm between engine
um
r
fo
en
ng
support and right longitudinal member.

t.
yi Co
op py
• The side surface of the engine support casting must be located
. C rig
ht ht
rig
parallel to support arm -1-. Dimension -b- must be identical at py by
co Vo
front and rear.
by lksw
cted agen
Prote AG.
– On gearbox side, ensure that edges of support arm -2- and

gearbox mounting -1- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for assembly mounting.
Install in reverse order of removal.
Torque settings
♦ ⇒ “2.1 Assembly overview - charge air system”, page 251
♦ ⇒ “2.7 Checking adjustment of assembly mountings (engine
and gearbox mountings)”, page 37

Jetta 2015 ➤
2.7 Checking adjustment of assembly

mountings (engine and gearbox mount‐
ings)
• There must be a distance -a- of 10 … 13 mm between engine
support and right longitudinal member.
• The cast edge on the engine support -a- must be aligned par‐
allel to support arm. Dimension -b- must be identical at front
and rear.
Note
Distance -a- can also be checked with a rod of suitable diameter.
Only when there is a complaint of noise (engine or gearbox con‐

tacts longitudinal member when travelling around bends) and
dimension -a- lies outside 10 … 13 mm:
olkswagen AG
en AG. V
– Adjusting assembly
olksmountings ⇒ page 35 . s no
wag doe
yV t gu
db ara
ir se 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
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.
AG. Volkswagen AG d
agen oes
Jetta 2015 ➤ olksw not
byV gu
ara
rised
- Edition 07.2019 nte
ho eo
aut ra
ss c
13 – Crankshaft group
ce
le
un
pt
an
d
itte
y li
erm
ab
1 Cylinder block (pulley end)
ility
ot p
wit
is n
h re
⇒ “1.1 Assembly overview - poly V-belt drive”, page 38
ole,
spec
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
t to the co
42
⇒ “1.3 Removing and installing poly-V belt”, page 43
rrectne
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 46
ss
⇒ “1.5 Removing and installing vibration damper”, page 46
o
cial p
f inform
⇒ “1.6 Removing and installing engine support”, page 48 mer
atio
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
om
n
page 50
c
i
or
n thi
te
⇒ “1.8 Removing and installing sealing flange on pulley end”,
sd
iva
o
r
page 52
p
cum
r
fo
en
ng
1.1 Assembly overview - poly V-belt drive

t.
yi Co
Cop py
ht. rig
⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without
rig ht
py by
o Vo
air conditioner compressor”, page 38 by c lksw
cted agen
Prote AG.
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with air
conditioner compressor”, page 40
1.1.1 Assembly overview - poly V-belt drive, vehicles without air conditioner com‐
pressor
38 Rep. gr.13 - Crankshaft group

Jetta 2015 ➤
1 - Bolt
❑ 150 Nm +180°
2 - Vibration damper
❑ Removing and installing
⇒ page 46
3 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Determine length of poly
V-belt according to ⇒ n AG. Volkswagen AG do
Electronic Parts Cata‐ lkswage es n
Vo ot g
logue depending on ver‐ ed
by ua
ran
sion of decoupler/free thoris tee
or
wheel pulley on alterna‐s au ac
tor s
ce
e
nl
pt
❑ Poly V-belt routing
du
an
itte
⇒ page 44
y li
erm
ab
ility
ot p
⇒ page 43
wit
, is n
h re
4 - Bolt
hole
spec
es, in part or in w
t to the co
❑ 20 Nm +90°
5 - Tensioning device for poly
rrectness of i
V-belt
❑ Pivot with socket to
l purpos
slacken poly V-belt

nf
ercia
o
⇒ page 46
rm
m
atio
m
6 - Bolt
o
n in
or c
❑ Specified torque ⇒
thi
e
Electrical system; Rep.

t
sd
iva
gr. 27 ; Alternator; As‐

r
rp
cu
o
sembly overview - alternator

f
en
ng
t.
yi Co
op
7 - Alternator C py
t. rig
gh ht
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
yri
p by
co Vo
by lksw
❑ With freewheel cted agen
Prote AG.
❑ Various versions of the decoupler/free wheel pulley, -A- or -B-, may be fitted depending on the type and
version of alternator ⇒ page 40
1. Cylinder block (pulley end) 39

Jetta 2015 ➤
Allocation of overrunning alternator pulley
1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioner com‐
pressor
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Determine length of poly
V-belt according to ⇒
Electronic Parts Cata‐
logue depending on ver‐
sion of decoupler/free
wheel pulley on alterna‐
tor n AG. Volkswagen AG do
swage es n
❑ Poly V-belt routing byV
olk ot g
ua
⇒ page 46 ir se
d ran
tee
ho
❑ Removing and installing aut or
ac
⇒ page 43 ss
ce
e
nl
pt
du
2 - Bolt
an
itte
y li

erm
ab
ility
ot p
❑ 150 Nm +180°
wit
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hole
spec

es, in part or in w
⇒ page 46
t to the co
4 - Tensioning device for poly

V-belt
rrectness of i
❑ Pivot with socket to

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slacken poly V-belt

⇒ page 46
nf
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5 - Bolt
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❑ 20 Nm +90°
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❑ Specified torque ⇒
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Electrical system; Rep. Cop py
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Prote AG.

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Jetta
or 2015 ➤
u
4-cylinder injection
ss
a
engine (1.4 l, 4V, EA211, turbocharger) - Edition ac
07.2019
ce
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nl
pt
du
gr. 27 ; Alternator; As‐
an
itte
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sembly overview - alternator
erm
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ility
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7 - Alternator
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❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
h re
hole
spec
❑ With freewheel
es, in part or in w
❑ Various versions of the decoupler/free wheel pulley, -A- or -B-, may be fitted depending on the type and
t to the co
version of alternator ⇒ page 41
8 - Dowel sleeve
rrectness of i
❑ For air conditioner compressor.
l purpos
9 - Air conditioner compressor

❑ Do not unscrew or disconnect refrigerant lines
nform
ercia
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioner compressor;
m
at
Removing and installing air conditioner compressor from and to bracket
om
ion
c
in t
10 - Bolt
or
his
ate
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐
do
priv
c
view - drive unit of air conditioner compressor .
um
for
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t.
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Cop py
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gh
Allocation of overrunning alternator pulley
ht
pyri by
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Prote AG.

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Jetta 2015 ➤ aut
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4-cylinder injection engine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019 s
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nl
pt
du
an
1.2 Assembly overview - sealing flange, belt pulley end
itte
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ility
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1 - Bolt
h re
hole
spec
es, in part or in w
❑ 150 Nm +180°
t to the co
rrectness of i
⇒ page 46 l purpos
3 - Seal
❑ For crankshaft on belt
nform
ercia
pulley end
m
at
om
io
⇒ page 50
n
c
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or
❑ Do not oil
his
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4 - Sealing flange at belt pulley

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end
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❑ Must seat on dowel . Cop py
pins.
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py by
Vo
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⇒ page 52 Prote AG.
5 - Bolt
❑ Different thread diame‐
ters ⇒ Electronic parts
catalogue (ETKA)
❑ Specified torque and
tightening sequence
⇒ page 42
6 - Seal
7 - Cylinder block
8 - Dowel pin
❑ Qty. 2
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 42
Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts -1 … 12- in stages:
Stage Component Specified torque/turning further angle
1 Bolts -1 to 12- Screw in by hand as far as stop
3 Bolts -7, 8- 20 Nm
4 Bolts -1 to 12- turn 90° further diagonally

Jetta 2015 ➤
Plug for “TDC” drilling in cylinder block at rear – specified torque

Plug with integrated seal -arrow-
– Renew if damaged
Bolt -arrow- 30 Nm
1.3 Removing and installing poly-V belt

⇒ “1.3.1 Removing and installing poly V-belt, vehicles without air
⇒ “1.3.2 Removing and installing poly V-belt, vehicles with air
n AG. Volkswagen AG age does
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1.3.1 Removing and installing poly V-belt, ve‐
ed
by Vol gu
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hicles without air conditioner compres‐
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pt

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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
a
com
ti
Removing
on in
r
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thi
– To slacken poly V-belt, turn tensioner anti-clockwise in

s
iva
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rp
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fo
– Lock tensioning device in place with locking pin - T10060 A- .

en
ng
t.
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op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted
– Remove poly V-belt.
agen
Prote AG.

Jetta 2015 ➤
Installing
Various versions of the overrunning alternator pulley, -A- or -B-,
may be fitted depending on the type and version of alternator.
Determine length of poly V-belt according to ⇒ Electronic Parts

Catalogue depending on version of decoupler/free wheel pulley
on alternator
– Fit poly V-belt as shown in illustration.
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
AG. Volkswagen AG d
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– Turn tensioning device in -direction of arrow-, and pull out ed by ara
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is
locking pin - T10060 A- . hor eo
aut ra
c
– Release tensioner. ss
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– Check that poly V-belt is properly seated. pt

an
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itte
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erm
– Start engine and check that poly V-belt runs properly. ab

ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
1.3.2 Removing and installing poly V-belt, ve‐

hicles with air conditioner compressor
ss o
cial p

inform
mer
atio
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n
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te
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
Removing
– Fit tool -3- onto hexagon of tensioner -1-.
wage es n
– To slacken poly V-belt push tool -3- in -direction
yV
olks of arrow-. ot g
ua
b
ed ran
– Lock tensioner -1- in place with locking
tho
ris pin - T10060 A- -2-. tee
or
au ac
– Remove poly V-belt -4-. ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installing
rrectness of i
Various versions of the overrunning alternator pulley, -A- or -B-,
l purpos
may be fitted depending on the type and version of alternator.

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

AG. Volkswagen AG d
agen oes
olksw not
Jetta 2015 ➤ d byV gu
ara
e
horis - Edition 07.2019 nte
eo
aut ra
ss c
Determine length of poly V-belt according to ⇒ Electronic Parts
ce
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un
Catalogue depending on version of decoupler/free wheel pulley
pt
an
d
on alternator
itte
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rm
ab
pe
ility
ot
wit
, is n
– Fit poly V-belt as shown in illustration.
h re
hole
spec
1- Vibration damper
es, in part or in w
t to the co
2- Tensioning device for poly V-belt
3- Alternator
rrectness of i
4- Air conditioner compressor
l purpos
– Use tool -3- to turn tensioner -1- in -direction of arrow-, and
pull out locking pin - T10060 A- -2-.
nform
ercia
– Release tension from tensioner -1-.

m
a
com
tion in
– Check that poly V-belt is properly seated.
r
te o
thi
s
iva
– Start engine and check that poly V-belt runs properly.
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.
1.4 Removing and installing tensioner for

poly V-belt
Removing
– Remove poly V-belt from tensioning device:
♦ Vehicles without air conditioner compressor ⇒ page 43
♦ Vehicles with air conditioner compressor ⇒ page 44
– Remove bolts -arrows- and detach poly V-belt tensioner -1-.
Installing
– Installing poly V-belt:
♦ Vehicles without air conditioner compressor ⇒ page 43
♦ Vehicles with air conditioner compressor ⇒ page 44
Torque settings
♦ ⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles with‐
out air conditioner compressor”, page 38
♦ ⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with
air conditioner compressor”, page 40
1.5 Removing and installing vibration damp‐

er

Jetta 2015 ➤
♦ Counter-hold tool - T10475-
AG. Volkswagen AG d
agen oes
olksw not
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Preparingthcounterhold
or
tool - T10475- eo
au ra
ss c
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
♦ Different types of vibration damper can be installed.
ility
ot p
wit
♦ For this reason, the counterhold tool - T10475- must be adap‐
, is n
h re
ted to the holes of the respective vibration damper.
hole
spec
es, in part or in w
t to the co
Version 1
– Convert counter-hold tool - T10475- -1- using inserts -
T10475/2- -2-. rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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cu
o
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f
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ng
Version 2
t.
yi Co
Cop py
Convert counter-hold tool - T10475- with inserts inserts -
t. rig
gh ht
yri by
T10475/1- and -T10475/2- as shown in illustration.
cop Vo
by lksw
cted agen
Prote
• To do this, use hole -A- or -B- of counter-hold tool - T10475-
AG.
-1- depending on type of vibration damper.

Removing
sulation .
– Remove poly V-belt ⇒ page 43 .
– Set engine to “TDC for cylinder no. 1” ⇒ page 109 .

Jetta 2015 ➤
– Loosen bolt -arrow- for vibration damper using counterhold -

T10475- .
– Unscrew bolt and remove vibration damper.
NOTICE
Risk of damage to engine caused by incorrect valve timing.
– Do not turn crankshaft out of TDC position.
Installing
– All contact surfaces between bolt, vibration damper and crank‐
shaft pulley must be free of oil and grease.
– Fit vibration damper, oil threads of bolt for vibration damper

and screw it in to stop by hand.
– Tighten bolt -arrow- for vibration damper using counterhold -
T10475- .
Further installation is carried out in reverse order of removal, ob‐
serving the following: swa
gen AG
. Volkswagen AG
does
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Vol gu
– Install poly V-belt ⇒ page
se
d b 43 .
y ara
nte
ri
ho eo
Torque settings aut ra
ss c
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 38
ce
le
un
pt
an
d
♦ Assembly overview - noise insulation ⇒ General body repairs,

itte
y li
rm
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -

ab
pe
ility
noise insulation
ot
wit
, is n
h re
hole
1.6 Removing and installing engine support

spec
es, in part or in w
t to the co
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
rrectness of i

l purpos

– Drain coolant ⇒ page 197 .
nform
ercia

m
a
com
tion in

r
te o
thi
– Remove tensioner for poly V-belt ⇒ page 46 .

s
iva
do
r
rp
cum
– Detach hoses from retainer -3-.

fo
en
ng
t.
yi Co
– Unscrew bolt -2-. t. Cop py
rig
gh ht
– Release clips -arrows- and remove upper toothed belt guard pyri by
Vo
co
-1-.
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Unscrew bolt -1-.

– Loosen hose clip -2- and pull off coolant hose.
lkswage es n
o ot g
byV ua
d ran
ir se
– Unscrew bolts -1- and remove bracket
tho -2- for catalytic con‐ tee
or
verter. ss
au ac
ce
le

un
pt
an
d
itte
y li
– Removing engine mounting ⇒ page 24 .
erm
ab
ility
ot p
– Tighten spindles slightly to take up weight of engine/gearbox
wit
is n
assembly; do not lift.
h re
ole,
– Loosen bolt -1- but do not remove.
spec
t to the co
rrectne
ss
– Swivel alternator -3- in -direction of arrow- towards front.
o
cial p
f inform
– Remove pendulum support ⇒ page 27 .
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.
– Unscrew bolts -arrows-.

Jetta 2015 ➤
– Unscrew bolts -1, 2, 3-.
– Loosen bolts -2- on gearbox mounting -1-.

– Push engine/gearbox assembly slightly towards left, and de‐
tach engine support.
Installing
Torque settings
♦ ⇒ “2.1 Assembly overview - toothed belt cover”, page 94
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 223
♦ ⇒ “2.1 Assembly overview - emission control”, page 309
♦ Assembly overview - alternator ⇒ Electrical system; Rep. gr.
27 ; Alternator; Assembly overview - alternator . . Volkswage n AG n AG d
wage oes
♦ Assembly overview - battery ⇒ Electricaly Vsystem;
olks Rep. gr. 27 ; not
gu
Battery; Assembly overview - battery
ise
d. b ara
nte
r
ho eo
aut ra
1.7 Renewing crankshaft oil seal - belt pul‐ ss c
ce
e
nl
ley end
pt
du
an
itte
y li
erm
ab

ility
ot p
♦ Assembly tool - T10485-

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
50
by lksw
cted agen
Rep. gr.13 - Crankshaft group Prote AG.
Jetta 2015 ➤
♦ Extractor hook - T20143-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
Procedure
pe
ility
ot
wit
, is n
– Remove toothed belt ⇒ page 99 .
h re
hole
– Detach crankshaft pulley -1- -arrow-.
spec
es, in part or in w
t to the co
NOTICE
rrectness of i
l purpos
nform
mercia
a
com
t
– Pry out seal using extractor hook -T20143/2- -arrow-.
ion in
r
te o
– Clean contact surface and sealing surface.
thi
s
iva
do
r
• Do not lubricate new seal.

rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit new seal in -direction of arrow- onto assembly sleeve -

T10485/2- .

Jetta 2015 ➤
– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

• Installation position: closed end of seal faces fitting sleeve.
– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
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un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Use fitting sleeve -T10485/1- and bolt -1- for poly V-belt pulley
, is n
h re
to pull in oil seal -2- onto stop.
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
– Fit crankshaft sprocket onto crankshaft.

thi
s
iva
do
• The contact surface between vibration damper and crankshaft

r
rp
cum
fo
toothed belt pulley must be free of oil and grease.

en
ng
t.
yi Co
• The machined surface -arrow- of crankshaft pulley must be Cop py
t. rig
positioned over the machined surface of the crankshaft jour‐ gh ht
yri by
nal.
op Vo
by c lksw
cted agen
Prote AG.
– Install toothed belt (adjust valve timing) ⇒ page 109 .
1.8 Removing and installing sealing flange

on pulley end
♦ Scraper
♦ Sealant ⇒ Electronic parts catalogue (ETKA)

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth or
ac Jetta 2015 ➤
ss 4-cylinder injection engine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
ce
le
un
pt
an
d
Removing
itte
y li
rm
ab
pe
ility
ot
wit
, is n
sulation .
h re
hole
spec
– Remove air conditioner compressor from bracket ⇒ Heating,
es, in part or in w
air conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐
t to the co
moving and installing air conditioner compressor from and to
bracket .
rrectness of i
– Remove toothed belt ⇒ page 99 .
l purpos
NOTICE
nform
ercia

m
a
com
tio
n 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.
– Unscrew bolts -1 … 12- and carefully remove sealing flange
from the glued joint.
– Drive out radial oil seal with sealing flange removed.
Installing
• The lubrication system can be soiled by sealant residue.
• Cover open section of sump with clean clothes.
– Remove sealant residue from sealing flange and sump (top
section).
– Remove any oil and grease from sealing surfaces.
– Observe use-by date of sealant.

– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).

Jetta 2015 ➤
– Slide gasket -1- onto dowel pins in cylinder block.

– Apply a thin bead of sealant at the edge of the joint between
the cylinder block and the sump -arrows-.
– Thinly coat lower sealing surface -arrow- on sealing flange

with sealant.
Note
Install the sealing flange within 5 minutes after the sealant has
been applied.
– Carefully fit gasket sealing flange onto dowel pins on cylinder

block.
– Tighten bolts for sealing flange ⇒ page 42 .
– Fit oil seal for crankshaft at belt pulley end ⇒ page 50 . agen
AG. Volkswagen AG d
oes
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by ara
– Fit crankshaft sprocket onto crankshaft. rised
nte
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ut
• The contact surface between vibration damper and
ss a crankshaft ra
c
ce
le
un
pt
an
d
• The machined surface -arrow- of crankshaft pulley must be

itte
y li
positioned over the machined surface of the crankshaft jour‐
erm
ab
nal.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
stalling air conditioner compressor .
– Install noise insulation ⇒ General body repairs, exterior; Rep. rrectne
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
ss
Torque settings
o
cial p
f in
♦ ⇒ Fig. ““Sealing flange at belt pulley end - Prescribed torque

form
mer
and tightening sequence”“ , page 42

atio
om
♦ Assembly overview - alternator ⇒ Electrical system; Rep. gr.

n
c
i
or
27 ; Alternator; Assembly overview - alternator .

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 55
⇒ “2.2 Assembly overview - drive plate”, page 56
⇒ “2.3 Removing and installing drive plate”, page 56
⇒ “2.4 Removing and installing flywheel”, page 58
⇒ “2.5 Removing and installing sealing flange on gearbox side”,
page 59
2.1 Assembly overview - cylinder block, gearbox end
Note
For assembly work, secure engine

agen
AGto engine
. Vo and
lkswagen AG dgearbox
o
support ⇒ page 18 .
w es n
olks ot g
byV ua
ed ran
ris tee
1 - Bolt tho or
au ac
ss
ce
le
un
pt
❑ 60 Nm +90°
an
d
itte
y li
erm
2 - Flywheel
ab
ility
ot p

wit
is n
⇒ page 58
h re
ole,
❑ Can only be fitted in one spec

position
t to the co
3 - Engine speed sender -

G28-
rrectne

⇒ page 319
ss
4 - Bolt
o
cial p
f i
❑ Specified torque
nform
⇒ page 314
mer
atio
m
5 - Dowel pin
o
n
c
i
or
❑ Qty. 2
thi
te
sd
iva
6 - Intermediate plate
pr
cum
r
fo
❑ Do not damage or bend

en
ng
t.
yi Co
when assembling. t. Cop py
rig
❑ Installing ⇒ page 56
gh ht
pyri by
Vo
co lksw
by
7 - Bolt cted agen
Prote AG.
tightening sequence:
⇒ page 56
8 - Sealing flange with sender
wheel and oil seal
❑ Renew sealing flange
complete with oil seal
and sender wheel only.
⇒ page 59
2. Cylinder block, gearbox end 55

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
Jetta 2015 ➤ ut
ho eo
ra
a
4-cylinder injection sengine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
s c
ce
e
nl
pt
du
Sealing flange on gearbox side - specified torque and tightening
an
itte
y li
sequence
erm
ab
ility
ot p
– Tighten bolts -1- to -6- in stages as follows:
wit
, is n
h re
Stage Component Specified torque
hole
spec
1 Bolts -1- to -6- Screw in by hand as far as stop
es, in part or in w
t to the co
2 Bolts -1- to -6- 10 Nm
rrectness of i
l purpos
nf
ercia
Installing intermediate plate
orm
m
atio
– Attach intermediate plate -1- to sealing flange -2- -arrow B-.
om
n in
or c
– Slide intermediate plate onto dowel sleeves -arrows A-.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2 Assembly overview - drive plate
1 - Shim
2 - Drive plate
❑ Fit using only washer
with recesses -3- (with‐
out shim -2-).
3 - Washer with recesses
4 - Bolts
❑ 60 Nm + 90° (bolts can
be turned further in sev‐
eral stages).
2.3 Removing and installing drive plate


Jetta 2015 ➤
♦ Clutch counterhold - VW558-
♦ Depth gauge
♦ Hexagon bolt M8 × 40 and hexagon nut M8
– Remove gearbox ⇒ Rep. gr. 37 ; Removing and installing
gearbox .
Preparing clutch counter-hold tool - VW558- :
– Tighten hexagon bolt M 8 × 40 -A- with a hexagon nut on clutch
counter-hold tool - VW558- .
lkswage es n
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Loosening and tightening drive plate:
o
ir se tee
th or
u
– Insert clutch counter-hold stool
s a - VW558- in cylinder block and ac
drive plate as shown.
ce
e
nl
pt
du
an
Installation position of counter hold: -A- to loosen, -B- to tighten.

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
rrectness of i
Installing drive plate:

l purpos
– Fit drive plate without washer -1- first.

– Fit used securing bolts -4- and tighten to 30 Nm.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Cop py
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Vo
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Prote AG.

Jetta 2015 ➤
– Check dimension -a- at three points, and calculate the average

value.
Specification: 18.8 to 20.4 mm
AG. Volkswagen AG d
Note lksw
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Measure through hole in drive plate
horise
down to valve timing housing. nte
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ss c
If the specification is attained, renew all securing bolts, and tight‐
ce
le
un
pt
en them.
an
d
itte
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rm
ab
pe
ility
If specification is not attained:
ot
wit
, is n
h re
– Remove drive plate again and fit shim -1-. Tighten bolts -4-
hole
spec
again to 30 Nm.
es, in part or in w
t to the co
– Repeat measurement. If the specification is attained, renew
all securing bolts, and tighten them.
Torque settings
rrectness of i
Drive plate bolt ⇒ Item 4 (page 56)
l purpos
nform
mercia
a
com
tion in
2.4 Removing and installing flywheel
r
te o
thi
s
iva
Special tools and workshop equipment required do

r
rp
cum
fo
en
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♦ Counter-hold tool - 3067-

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

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
Removing olksw not
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• Gearbox removed rise nte
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au ra
– Insert counterhold - 3067- in hole on cylinder block -B-. ss c
ce
le
un
pt
– Loosen and remove flywheel bolts.
an
d
itte
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rm
Installing
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Flywheel with sender wheel can only be fitted in one position.
l purpos
– Insert counterhold - 3067- in hole in cylinder block -A-.

Torque settings
nform
ercia
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page

m
a
com
ti
55
on in
r
te o
thi
s
iva
2.5 Removing and installing sealing flange
do
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rp
cum
on gearbox side
fo
en
ng
t.
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op
C py
t. rig
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♦ Flared ring spanner tool insert AF 24 - V.A.G 1332/11- cop Vo
by lksw
cted agen
Prote AG.
♦ Depth gauge - VAS 6082-

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
♦ Locating bolt - T10340- orise nte
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h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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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
♦ Qty. 3 M6 × 35 bolts.
l purpos
Procedure
nform
ercia
• Gearbox is removed.
m
at
– Remove flywheel ⇒ page 58 .
om
ion
c
in t
r
– Remove intermediate plate -1- from dowel sleeves

o
his
e
-arrows A-.
at
do
priv
cum
or
– Guide intermediate plate -1- upwards.

f
en
ng
t.
yi Co
– While doing so, pull retaining lug -arrow B- of intermediate Cop py
plate -1- out of recess behind sealing flange.
t. rig
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pyri by
Vo
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– Set crankshaft to “TDC” position ⇒ page 112 .
lksw
cted agen
Prote AG.
– Remove sump (bottom section) ⇒ page 170 .
– Remove upper part of sump ⇒ page 174 .
– Remove engine speed sender - G28- ⇒ page 319 .
– Unscrew bolts -arrows- for sealing flange -1-.

Jetta 2015 ➤
– To press off, screw qty. 3 M6 × 35 bolts -arrows- into sealing

flange -1-.
– The sealing flange -1- is pressed off crankshaft -3- together
with the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Pressing in sealing flange with sender wheel
AG. Volkswagen AG d
agen oes
olksw not
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♦ The sealing flange with a PTFE seal is equipped s a with a sealing
u ra
c
lip support ring -2-. This support ring serves as
s a fitting sleeve
ce
e
and must not be removed prior to installation.

nl
pt
du
an
itte
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♦ Sealing flange and sender wheel -1- must not be separated or
erm
ab
turned after removal from packaging.
ility
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wit
, is n
♦ The sender wheel -1- is held in its installation position on the
h re
locating pin of the assembly tool - T10134- ⇒ page 61 .
hole
spec
es, in part or in w
♦ Sealing flange and oil seal form one unit and must only be
t to the co
renewed together with the sender wheel.
♦ The assembly tool - T10134- is held in its position relative to
the crankshaft by a guide pin inserted into a hole in the crank‐
rrectness of i
shaft ⇒ page 61 .
l purpos
Components of assembly tool - T10134- :
nf
ercia
orm
A - Clamping surface
m
atio
om
n in
B - Nut
or c
thi
te
C - Assembly housing
sd
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D-
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Locating pin
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Cop py
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E - Hexagon socket head bolt (qty. 2)
rig
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Vo
co
F-
by lksw
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Prote
Guide pin for petrol engines (red knob)
AG.
G - Guide pin for diesel engines (black knob)

H - Knurled screws (qty. 3)
I - Inner part
Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.

lkswage es n
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ir se tee
o
Jettaau 2015 ➤
th or
ac
ss
ce
e
nl
pt
du
an
– Clamp assembly device - T10134- at clamping surface -A- of
itte
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threaded spindle in a vice -1-.
erm
ab
ility
ot p
– Push assembly housing -C- downwards until it rests against
wit
, is n
nut -B-.
h re
hole
spec
• Inner part of assembly tool and assembly housing must be at
es, in part or in w
same height.
t to the co
rrectness of i
l purpos
nf
ercia
o
– If fitted, remove securing clip -arrow- from new sealing flange.
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
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rp
cu
Do not take the sender wheel out of the sealing flange or rotate it
o
m
f
out of position.
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Place sealing flange with front side facing down on a clean

level surface.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against flat surface.
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.

Jetta 2015 ➤
– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
• The sealing flange must rest flat against the assembly tool.
– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
– This prevents the locating pin from slipping out of the sender
wheel hole.
– When installing sealing flange, ensure that sender wheel re‐
mains fixed in assembly tool. n AG. Volkswagen AG age does
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Mounting assembly tool - T10134- with sealing flange -1- on
e
nl
pt
du
crankshaft flange
an
itte
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erm
ab
• The crankshaft flange must be free of grease and oil.
ility
ot p
wit
• Engine is at “TDC” position ⇒ page 109 .
, is n
h re
hole
– Screw on nut -B- until it reaches end of threaded spindle. spec

es, in part or in w
– Press threaded spindle of assembly tool - T10134- in

t to the co
-direction of arrow-, until nut -B- rests against assembly hous‐

ing -C-.
rrectness of i
– Align flat side of assembly housing to sealing surface of cyl‐

inder block on sump side.
l purpos
– Attach assembly tool - T10134- together with sealing flange

nform
ercia
-1- to crankshaft flange -2-.

m
at
– To do this, screw hexagon socket head bolts -E- into crank‐

om
ion
shaft flange (approx. 5 full turns) using a hexagon key.

c
in t
or
his
te
– Push guide pin for petrol engines (red knob) -F- into crankshaft
a
do
riv
flange.
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
– To guide sealing flange -1-, screw two M6

AG. Vxol35
kswmm bolts
agen AG do -2-
agen
into cylinder block. Volksw es n
ot g
y ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
Bolt assembly tool - T10134- onto crankshaft flange
– Push assembly housing -C- by hand in -direction of arrow- until
rrectness of i
sealing lip support ring -1- rests against crankshaft flange
l purpos
-2-.
– Make sure that guide pin for petrol engines (red knob) -F- is
nform
ercia
properly seated in hole in crankshaft. This ensures that the

sender wheel reaches its final installation position.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
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rp
cum
The guide pin for diesel engines (black knob) must not be inserted
fo
en
ng
in threaded hole of crankshaft.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Tighten the two hexagon socket head bolts of assembly tool p by
o Vo
by c
hand-tight.
lksw
cted agen
Prote AG.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.
Pressing sender wheel onto crankshaft flange using assembly

tool - T10134-
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After the nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block and sealing flange -1-.
Checking sender wheel installation position on crankshaft

– Screw on nut -B- until it reaches end of threaded spindle.
– Unscrew the two bolts -2- from cylinder block.
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.

AG. Volkswagen AG d Jetta 2015 ➤
agen
ksw 4-cylinder injection enginenot (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
oes
Vol
by gu
d ara
ise nte
– Position
ut
hor
depth gauge - VAS 6082- on crankshaft flange
eo -2-.
a 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
– Measure distance -a- between crankshaft flange -2- and send‐
l purpos
er wheel -1-.
• Specification: dimension -a- = 0.5 mm
nform
ercia
– If specification is not achieved, press sender wheel further in

m
at
om
⇒ page 65 .
ion
c
in t
or
– If specification is achieved, proceed with subsequent work
his
ate
steps ⇒ page 66 .
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote
Re-pressing sender wheel
AG.
– Secure assembly tool - T10134- on crankshaft flange -1-.

– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool - T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
– Push guide pin for petrol engines (red knob) -F- into crankshaft
flange.
– Screw knurled screws -H- into sealing flange -1-.
– To guide sealing flange, screw two M6 x 35 mm bolts -2- into
cylinder block.

Jetta 2015 ➤
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

– Check sender wheel installation position on the crankshaft
again ⇒ page 64 .
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 64 .
Assembling lkswage es n
o ot g
byV ua
– Tighten bolts for sealing flange ⇒ page 56 . ir se
d ran
tee
tho
u or
– Install upper part of sump ⇒ page 174 . ss
a ac
ce
le
– Install bottom section of sump ⇒ page 170 .
un
pt
an
d
itte
y li
– Install intermediate plate ⇒ page 56 .
erm
ab
ility
ot p
– Install flywheel ⇒ page 58 .
wit
is n
h re
Torque settings
ole,
spec
♦ ⇒ Fig. ““Sealing flange on gearbox side - specified torque and
t to the co
tightening sequence”“ , page 56
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - specified tor‐
que”“ , page 96
rrectne
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
55
ss o
cial p
f
♦ Engine speed sender - G28-
inform
⇒ “1.1 Assembly overview - ignition system”, page 314
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.

Jetta 2015 ➤
3 Crankshaft
⇒ “3.1 Crankshaft dimensions”, page 67
⇒ “3.2 Renewing needle bearing in crankshaft”, page 67
⇒ “3.3 Measuring axial clearance of crankshaft”, page 70
3.1 Crankshaft dimensions

NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
AG. Volkswagen AG d
bearing pedestals of the cylinder
lksw
agenblock will be deformed,
oes
not and
damage to the bearings d b will
yV
o
result. gu
ara
se nte
– Never removeththe ori crankshaft. eo
au ra
c
ss
ce
Measuring the crankshaft bearing clearance is not possible with
e
nl
pt
du
normal workshop equipment.
an
itte
y li
erm
ab
Honing dimension Conrod bearing journal diameter
ility
ot p
mm
wit
, is n
h re
Basic dimension 48.00 -0.022
hole
spec
-0.042
es, in part or in w
t to the co
3.2 Renewing needle bearing in crankshaft
Only vehicles with a dual clutch gearbox
rrectness of i
l purpos
Note
nform
ercia
For vehicles with manual gearbox, no needle bearing must be

installed in the crankshaft.
m
at
om
ion
c
in t
or

his
ate
do
riv
♦ Pin - VW 207 C-
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Crankshaft 67
Jetta 2015 ➤
♦ Extractor - Kukko 21/2-
♦ Adapter KUKKO - 22/1-
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
Removing
erm
ab
ility
ot p
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
wit
is n
gearbox .
h re
ole,
Condition
spec
• Always renew needle bearing -arrow- after separating engine
t to the co
and gearbox.
• The front edges of the inner puller must be free of chips.
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.

Jetta 2015 ➤
Pulling out needle roller bearing

– Using a commercially available internal puller, e.g. KUKKO -
21/2- , and counter support, e.g. KUKKO - 22/1- , pull needle
bearing -1- out of crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
ise nte
Note uthor eo
ra
s a c
s
The inscribed side of an open needle bearing must be visible
ce
e
nl
pt
du
when installed. Bearings which are sealed on one side must be
an
itte
y li
driven in with the sealed side facing the crankshaft.
erm
ab
ility
ot p
– Clean bearing seat in crankshaft and apply as thin coating of
wit
, is n
h re
grease.
hole
spec
– Using drift - VW 207 C- , drive needle bearing into crankshaft
es, in part or in w
as far as installation depth -a-.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
Installation depth: dimension -a- = 2.0 mm

atio
om
n in
or c
thi
te
Note
sd
iva
o
r
rp
cu
o
m
f
If the needle bearing has been driven in too far, it must be re‐
en
ng
t.
yi
newed because it will be damaged when it is pulled out.
Co
Cop py
t. rig
gh ht
pyri by
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
co Vo
by lksw
cted
box; Installing gearbox .
agen
Prote AG.
3. Crankshaft 69
Jetta 2015 ➤
3.3 Measuring axial clearance of crankshaft

NOTICE
Risk of damage to bearing pedestals when the crankshaft is
removed.
If the bolts of the crankshaft bearing cap are loosened, the
bearing pedestals of the cylinder block will be deformed, and
damage to the bearings will result.
– Never remove the crankshaft.

♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
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
Procedure
spec
es, in part or in w
– Screw dial gauge - VAS 6079- with universal dial gauge brack‐
t to the co
et - VW 387- to cylinder block as shown in the illustration.
– Position dial gauge against crank web.
rrectness of i
– Press crankshaft against dial gauge by hand and set gauge to

l purpos
“0”.
– Push crankshaft away from dial gauge and read off measured
nform
ercia
value.
m
• Axial clearance: 0.066 to 0.233 mm

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.

Jetta 2015 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 71
⇒ “4.2 Removing and installing pistons”, page 73
⇒ “4.3 Checking pistons and cylinder bores”, page 74
⇒ “4.4 Separating new conrod”, page 75
⇒ “4.5 Checking radial clearance of conrods”, page 75
⇒ “4.6 Removing and installing oil spray jets”, page 76
4.1 Assembly overview - pistons and conrods
1 - Bolts
❑ Use old bolts to meas‐
ure radial clearance,
and tighten them with‐
out turning further angle
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure AG. Volkswagen AG d
(cracking) separating lksw
agen oes
not
the cap from the conrod. d byV
o gu
ara
e nte
❑ Mark allocation to cylin‐ horis
eo
der and conrod in colour aut ra
s c
-B-. s ce
le
un
pt
❑ Installation position: Lug
an
d
itte
-A- on conrod bearing

y li
erm
ab
cap faces towards pul‐
ility
ot p
ley end
wit
is n
h re
3 - Bearing bushes
ole,
spec
❑ Fitting position
⇒ page 72
t to the co
❑ Renew worn bearing

shells
rrectne
❑ Ensure firm seating

4 - Connecting rod
ss o
❑ With industrially
cial p
f in
cracked conrod bearing

form
mer
cap
atio
m
❑ Renew as set only.

o
n
c
i
or
❑ Mark allocation to cylin‐

thi
te
sd
a
der and conrod bearing cap in colour -B-.

iv
o
pr
cum
❑ Measuring radial clearance ⇒ page 75

r
fo
en
ng
t.
yi
❑ Separating new conrod ⇒ page 75 .
Co
Cop py
.
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end
ht rig
rig ht
py by
co Vo
5 - Retaining ring
by lksw
cted agen
Prote AG.
❑ Qty. 2
4. Pistons and conrods 71

Jetta 2015 ➤
6 - Piston pin
7 - Piston
❑ Mark installation position and cylinder number AG.⇒
Vopage
lkswag72
en A.G
agen does
ksw
❑ Removing and installing ⇒ page b73 yV
ol not
gu
ara
ed
❑ Checking piston and cylinder horibore
s ⇒ page 74 nte
e t or
au a
8 - Piston rings ss c
ce
e
❑ Compression rings
nl
pt
du
an
itte
❑ Measuring ring gap ⇒ page 74
y li
erm
ab
❑ Measuring ring-to-groove clearance ⇒ page 74
ility
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wit
❑ Use commercially available piston ring pliers to remove and install.
, is n
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❑ Installation position: marking “TOP” or side with lettering towards piston crown
hole
spec
❑ Offset gaps by 120°
es, in part or in w
t to the co
9 - Piston ring
❑ Oil scraper ring
rrectness of i
❑ Measuring ring gap ⇒ page 74
l purpos
❑ Measuring ring-to-groove clearance ⇒ page 74

❑ Use piston ring pliers to remove and install.
nform
ercia
❑ Installation position: marking “TOP” or side with lettering towards piston crown
m
❑ Offset gap 120° relative to lower compression ring
at
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Installation position and allocation of piston to cylinder

p
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• If used pistons are to be reinstalled, use paint to mark their

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allocation to the respective cylinder on the piston crown. Do Cop py
not use indentation, scratches, notches, or similar to mark pis‐ ht. rig
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• Arrow on piston crown points to pulley end -arrow-.
Prote AG.
Bearing shells - installation position

– Centre bearing shells on conrod and on conrod bearing cap.
• Dimension -a- must be the same as dimension -a-.

Jetta 2015 ➤
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve
2- Oil spray jet (for cooling of pistons)
Bolt with pressure 27 Nm
relief valve
Removing and installing ⇒ page 76 .
4.2 Removing and installing pistons

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

Removing
– Remove cylinder head ⇒ page 83 .
G. Volkswage
– Remove upper part of sump ⇒ page l174
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– Mark piston installation position
ut
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and corresponding cylinder tee
or
number. ss a ac
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– Mark installation position and matching of cylinder and conrod

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bearing cap to conrod ⇒ Item 4 (page 71) .

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– Remove conrod bearing cap and withdraw piston and conrod

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upwards.
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hole
spec
Note
es, in part or in w
t to the co
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
rrectness of i
– Remove retaining ring from piston pin eye.

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– Drive out piston pin using drift - VW 222 A- .

nf
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Installing
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– Oil running surfaces of bearing shells.

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– Install piston with commercially available piston ring clamp,

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noting installation position ⇒ page 72 . C py
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4. Pistons and conrods
AG.
Jetta 2015 ➤
– Install conrod bearing cap, noting installation position

⇒ Item 2 (page 71) .
– Install cylinder head ⇒ page 83 .
– Install upper part of sump ⇒ page 174 .
Torque settings
♦ ⇒ Fig. ““Oil spray jet and pressure relief valve”“ , page 73
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 71
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 166
4.3 Checking pistons and cylinder bores

Checking piston
– Using an external micrometre, measure approx. 10 mm from
lower edge, offset 90° from piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston diameter, mm
Specification 74.421)
• 1) Dimensions without coating
• Piston manufacturer Federal Mogul (thickness of 0.018 mm
per side)
• Piston manufacturer Mahle (thickness of 0.015 mm per side)
Measuring piston ring gap AG. Volkswagen AG d

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– Push piston ringbyatV right angles to cylinder wall from
ol
gu above
ara
down into cylinder
rised
bore to approx. 15 mm from bottom ntend
ee of
cylinder. autho
or
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– Push in using a piston without piston rings.
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Piston ring New Wear limit

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mm mm
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compression ring 0.20 +0.15 1.0

wit
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Oil scraper ring (2 parts) 0.20 +0.20 3.0

hole
spec
es, in part or in w
Oil scraper ring (3 parts) 0.50 +/-0.25 3.0

t to the co
Measuring ring-to-groove clearance

rrectness of i
– Clean annular groove of piston before check.

l purpos
Piston ring New Wear limit

mm mm
nform
ercia
1st compression ring (piston 0.050 … 0.090 0.15

m
at
ring manufacturer Federal

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Mogul)
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1st compression ring (piston 0.035 … 0.085 0.15

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ring manufacturer Mahle)

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2nd compression ring 0.030 … 0.070 0.15

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Oil scraper rings (3 parts) Cannot be measured
Cop py
t. rig
gh ht
Oil scraper rings (2 parts) yri
0.04 … 0.08
p by
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Prote AG.

Jetta 2015 ➤
Measuring cylinder bore
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Using cylinder gauge - VAS 6078- take measurements at 3

positions diagonally in lateral direction -A- and longitudinal di‐
rection -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 74.5 + 0.015 1)
+0.005
AG. Volkswagen AG d
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Do not measure cylinder bores when rise cylinder block is mounted nte
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on engine and gearbox support
s a - VAS 6095- , as measurements
ut ra
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may be incorrect. s
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4.4 Separating new conrod
ab
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On new conrods it is possible that the breaking point is not fully
is n
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separated. Proceed as follows if the conrod bearing cap cannot
ole,
spec
be removed by hand:
t to the co
– To avoid damage, gently clamp conrod in a vice with protection
jaws, as shown in illustration.
• Clamp conrod below dashed line.
rrectne
– Unscrew bolts -arrows- around 5 turns.
ss o
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f inform
mer
– Using a plastic hammer, carefully knock against conrod bear‐

atio
m
ing cap -arrow- until conrod bearing cap is loose.

o
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Cop py
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Prote AG.
4.5 Checking radial clearance of conrods

♦ Plastigage
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.

Jetta 2015 ➤
– Place a Plastigage corresponding to the width of the bearing

on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts
⇒ Item 1 (page 71) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
• Radial clearance: 0.028 to 0.065 mm.
– Renew conrod bolts.
4.6 Removing and installing oil spray jets

♦ Hexagon key - T10545-
Removing
sulation .
– Remove upper part of sump ⇒ page 174 and detach baffle
plate.
– Turn crankshaft via vibration damper in direction of engine ro‐
tation -arrow- until the respective bolt is accessible.
wage e
– Unscrew pressure relief valve -1-y Vusing socket - T10545- . s not gu
olks
b ara
ed
– Remove oil spray jet -2-. horis nte
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NOTICE
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Risk of damage to oil spray jets caused by deformation.

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– Do not bend oil spray jets.

wit
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spec

t to the co
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cial p
f inform
mer
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Cop py
ht. rig
rig ht
py by
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76
Prote AG.
Rep. gr.13 - Crankshaft group
Jetta 2015 ➤
• Installation position: align leading edge of oil spray jet -2- with
machined surface of cylinder block.
1- Bolt with pressure relief valve
2- Oil spray jet
– Install upper part of sump ⇒ page 174 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
tion .
Torque settings
♦ ⇒ Fig. ““Oil spray jet and pressure relief valve”“ , page 73
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 71
AG. Volkswagen AG d
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Cop py
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Prote AG.

Jetta 2015 ➤
15 – Cylinder head, valve gear

1 Cylinder head
n AG. Volkswagen A
⇒ “1.1 Assembly overview
olks
wag-ecylinder head”, page
G do
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o V t gu
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⇒ “1.2 Assembly
ris overview - camshaft housing”, page 80nte
ed ra
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⇒ “1.3 Removing
ss
au and installing cylinder head”, page 83 ra
c
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⇒ “1.4 Removing and installing camshaft housing”, page 87

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⇒ “1.5 Checking compression”, page 91
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1.1 Assembly overview - cylinder head
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Note
es, in part or in w
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♦ The camshafts must not be removed individually.
rrectness of i
♦ In the event of repair, the camshaft housing must be renewed
completely.
l purpos
nform
ercia
1 - Cylinder head gasket

m

at
om
⇒ page 83
on
c
in t
or
❑ Observe installation po‐

his
ate
sition: Part number to

do
priv
cylinder head
um
for
en
ng
t.
2 - Dowel sleeve
yi Co
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❑ Qty. 2 ht. rig
rig ht
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3 - Cylinder head
by lksw
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⇒ page 83
❑ Check for distortion
⇒ page 79 .
4 - Dowel pins
5 - Seal
❑ With oil strainer
❑ The oil strainer is fitted
only if the cylinder head
has the appropriate re‐
cess.
❑ Cylinder heads without
recess do not require an
oil strainer.
❑ Inserted into cylinder
head
6 - Seal
7 - Camshaft case
⇒ page 87
8 - Bolt
tightening sequence ⇒ page 83
78 Rep. gr.15 - Cylinder head, valve gear

Jetta 2015 ➤
❑ Different lengths installed
9 - Bolt
❑ Sequence when loosening ⇒ page 86 .
Cylinder head - specified torque and sequence

1 Bolts -1 to 10- 40 Nm
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler ogauge to
measure cylinder head for distortion at several G. V lkswagen AG d
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• Max. permissible distortion: 0.05semm
db
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spec
t to the co
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cial p
f inform
mer
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or
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
1. Cylinder head 79
Jetta 2015 ➤
1.2 Assembly overview - camshaft housing

⇒ “1.2.1 Assembly overview - camshaft housing, vehicles without
adjustable exhaust camshaft”, page 80
⇒ “1.2.2 Assembly overview - camshaft housing, vehicles with
1.2.1 Assembly overview - camshaft housing, vehicles without adjustable ex‐

haust camshaft
1 - Bolt
tightening sequence
⇒ page 81
❑ Different lengths instal‐
led
2 - Inlet camshaft control valve
1 - N205-
⇒ page 153
3 - Bolt
❑ 8 Nm
4 - Camshaft case
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⇒ page 87 yV
olks ot g
u b ara
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5 - Hall sender - G40-
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❑ Removing ss and installing
a ac
⇒ page 318
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6 - Bolt
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❑ 8 Nm
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7 - Seal
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❑ For exhaust camshaft,

hole
spec
gearbox end
es, in part or in w
t to the co

⇒ page 139
8 - Crankshaft
rrectness of i
❑ For coolant pump

l purpos

⇒ page 219
nform
ercia
9 - Bolt
m
a
com
ion in
⇒ page 206
r
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thi
s
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10 - Bolt
do
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rp
cum
❑ 8 Nm
fo
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ng
t.
yi Co
11 - Cap t. Cop py
rig
gh ht
12 - O-ring yri
p by
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❑ Renew after removal cted agen
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13 - Seal

AG. Volkswagen AG d
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horis Jetta 2015
eo ➤
ut
ss a (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
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nl
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14 - Dowel pin
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15 - Seal
ab
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❑ The oil strainer is fitted only if the cylinder head has the appropriate recess.
hole
spec
❑ Cylinder heads without recess do not require an oil strainer.
es, in part or in w
t to the co
❑ Inserted into cylinder head
16 - Seal
rrectness of i
❑ For inlet camshaft (pulley end)
❑ Renew after removal ⇒ page 136
17 - Seal l purpos
nf
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❑ For exhaust camshaft (pulley end)
orm
m
atio
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n in
18 - Cap
or c
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Camshaft housing - specified torque and tightening sequence
f
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t.
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op
1- Bolts -1 to 4-: M6 × 52 C py
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2- Bolts -5 to 15-: M6 × 65 op Vo
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AG.
Note
Note different bolt lengths.

1 Bolts -1 to 15- 10 Nm
1. Cylinder head 81
Jetta 2015 ➤
1.2.2 Assembly overview - camshaft housing, vehicles with adjustable exhaust

camshaft
1 - Exhaust camshaft control

valve 1 - N318-
⇒ page 154
2 - Bolt
❑ 8 Nm
1 - N205-
⇒ page 153
4 - Camshaft case
⇒ page 87
5 - Hall sender 3 - G300-
AG. Volkswagen AG d
❑ Removing and installing lksw
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not
⇒ page 318 d by Vo gu
ara
rise nte
6 - Bolt utho eo
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❑ 8 Nm ss c
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ab
⇒ page 318
ility
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wit
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8 - Seal
h re
hole
❑ For exhaust camshaft,
spec
gearbox end
es, in part or in w
t to the co
⇒ page 139
rrectness of i
9 - Crankshaft
l purpos

⇒ page 219
nf
ercia
orm
10 - Bolt
m
atio
m

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or c
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11 - Bolt
t
sd
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❑ 8 Nm
rp
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f
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12 - Cap
t.
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Cop py
t.
13 - O-ring
rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
14 - Seal
15 - Dowel pin
16 - Seal
❑ The oil strainer is fitted only if the cylinder head has the appropriate recess.
❑ Cylinder heads without recess do not require an oil strainer.
❑ Inserted into cylinder head

Jetta 2015 ➤
17 - Seal
❑ For inlet camshaft
18 - Seal
❑ For exhaust camshaft (pulley end) AG. Volkswagen AG d
agen oes
❑ Renew after removal ⇒ page 138 olksw not
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19 - Cap horis nte
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20 - Bolt ss c
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❑ Different lengths installed
pt
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Camshaft housing - specified torque and tightening sequence
hole
spec
1- Bolts -1 to 4-: M6 × 52
es, in part or in w
t to the co
2- Bolts -5 to 15-: M6 × 65
rrectness of i
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Note
nform
ercia
Note different bolt lengths.

m
at
om
io
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at
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1 Bolts -1 to 15- 10 Nm
um
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Cop py
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1.3 Removing and installing cylinder head
co Vo
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Prote AG.
♦ Bit XZN 12 - T40270-
1. Cylinder head 83
Jetta 2015 ➤
♦ Engine bung set - VAS 6122-
Removing n AG. Volkswagen AG do

lkswage es n
Vothe same place when installing. ot g
– Fit all heat shield sleeves d byin ua
ran
ir se tee
– Seal open channels/ports
utho
using suitable plugs from engine or
ac
a
bung set - VAS 6122-
ss .
ce
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nl
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ab
– Cover the openings in the gearbox with a cloth to prevent any
ility
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fluid entering the clutch housing.
wit
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hole
– Remove camshaft housing ⇒ page 87 .
spec
es, in part or in w
– Remove intake manifold ⇒ page 274 .
t to the co
– Disconnect connectors:
1- On oil pressure switch for reduced oil pressure - F378- rrectness of i
2- On fuel pressure sender - G247-

l purpos
3- At injectors
nform
mercia
at
om
ion
c
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ate
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t.
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op py
– Unscrew bolt -2- and remove screw-type clip. t. C rig
gh ht
pyri by
co Vo
by lksw
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verter. Prote AG.

AG. Volkswagen AG d Jetta 2015 ➤
agen
Volksw (1.4 l, 4V, EA211, turbocharger)
oes
not - Edition 07.2019
y gu
db ara
ise nte
– Unscrew bolts -arrows- and remove tho heat
r
shield for right drive eo
shaft. s au ra
c
s
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– Separate electrical connector -4- on oil pressure switch - F1-
nl
pt
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an
-3-.
itte
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– Remove vacuum pump, if fitted.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove bolts -arrows- and detach oil supply line -1- and oil
l purpos
return line -2-.
nf
ercia
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– Disconnect connectors -1- and -2-:
AG.
1 - For coolant temperature sender - G62-

2 - For charge pressure positioner - V465-
– Unscrew bolt -1- from engine support.
1. Cylinder head 85
Jetta 2015 ➤
– Loosen cylinder head bolts in the sequence -1 to 10- and un‐

screw.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Note
Remove any coolant residue on the pistons and cylinder wall im‐
mediately with a cloth.
Installing
Note
♦ Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block. n AG. Volkswagen AG do
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♦ Ensure that no long scores or scratches are made on theisesur‐
d b ua
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faces. thor tee
or
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♦ Avoid damage to cylinder block. ss
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pt
♦ No oil or coolant must be allowed to remain in the blind holes
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for the cylinder head bolts in the cylinder block.
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ab
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♦ Ensure that cylinder head gasket seals properly:
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♦ Carefully remove remains of emery and abrasives.
h re
ole,
spec
♦ Do not remove new cylinder head gasket from packaging until

it is ready to be fitted.
t to the co
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
rrectne
gasket.
♦ When installing a replacement cylinder head, the contact sur‐
ss
faces between hydraulic compensation elements, roller rocker
o
cial p
f i
fingers and cams must be oiled before installing the camshaft
nform
housing.
mer
atio
om
n
c
– Renew bolts that are tightened with turning further angle. i

or
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te
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– Renew self-locking nuts as well as gaskets, seals and O-rings.

iva
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– Do not reuse coolant which has been drained off.

en
ng
t.
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Cop py
t. rig
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Vo
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cted agen
Prote AG.

Jetta 2015 ➤
– Fit cylinder head gasket -1-.

♦ Note centring pins in cylinder block -arrows-.
♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
– If crankshaft has since been turned, position cylinder number
1 piston to TDC and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert cylinder head bolts, and tighten them by hand.
– Tighten bolts for cylinder head ⇒ page 79 .
Note
After repair work it is not necessary to retighten the cylinder head

bolts.

serving the following:
– Install camshaft housing ⇒ page 87 . . Volkswagen AG
gen AG does
swa
– Install intake manifold ⇒ page 274 . byV
olk not
gu
d ara
ise nte
– Change engine oil ⇒ Maintenanceth;oBooklet .
r eo
au ra
– Add coolant ⇒ page 197 . ss c
ce
le
un
pt
Torque settings
an
d
itte
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erm
♦ ⇒ Fig. ““Engine support - specified torques and tightening se‐
ab
ility
quence”“ , page 24
ot p
wit
is n
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 78
h re
ole,
spec
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 236
t to the co
♦ ⇒ “4.1 Assembly overview - intake manifold”, page 273
rrectne
♦ ⇒ Fig. ““Installing catalytic converter - specified torque and
sequence”“ , page 310
ss o
♦ Assembly overview - drive shaft ⇒ Running gear, axles, steer‐

cial p
f in
ing; Rep. gr. 40 ; Drive shaft; Assembly overview - drive shaft

form
mer
atio
m
1.4 Removing and installing camshaft hous‐

o
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c
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ing
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Removing
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– Remove coolant pump ⇒ page 212 .
Co
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– Remove air filter housing ⇒ page 271 . rig ht
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– Remove ignition coils ⇒ page 315 .
cted agen
Prote AG.
– Remove toothed belt from camshafts ⇒ page 130 .
1. Cylinder head 87
Jetta 2015 ➤
– Disconnect electrical connector -1-.

– Detach hose clip -2- and pull off hose.
– Remove high-pressure pipe -3- ⇒ page 294 .
– Open retainer -1-, and remove coolant hose -2-.

– Unscrew bolts -arrows- using ratchet insert 1/4 inch - VAS
6234- and socket T 30 - T10405- .
– Remove connection -1- upwards.
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– If fitted, release hose clip -2-, and remove coolant hose.

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– Remove bolts -arrows- and pivot coolant lines -1- to right side.
ot p
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spec
es, in part or in w
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ate
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priv
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for
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t.
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by
cted agen
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AG. Volkswagen AG d
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olksw not
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ed b ara
nt
Jetta 2015 ➤
ris
ut
ho 4-cylinder injection engine (1.4 l, 4V,eeEA211,
or turbocharger) - Edition 07.2019
a ac
ss
– Unscrew bolts -arrows-, and remove heat shield -1-.
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– Disconnect connector -arrow- from intake manifold sender -
nf
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GX9- .
orm
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2 - For camshaft control valve 1 - N205- and exhaust camshaft
control valve 1 - N318-
4 - For Hall sender - G40- and Hall sender 3 - G300-
– Remove bolt -3-, move wiring harness clear and place to left
side.
– Pull out dipstick -1-.
– Loosen bolts for camshaft housing in the sequence -15 to 1-

and unscrew.
– Carefully detach camshaft housing from adhesive bond and
remove it.
– Mark allocation of roller rocker fingers and compensation ele‐
ments for reinstallation.
– Remove roller rocker fingers together with compensation ele‐
ments and place them on a clean surface.
Installing
• Renew gasket and seal with oil strainer.
– Check “TDC” position of camshaft and crankshaft:
1. Cylinder head 89
Jetta 2015 ➤
• Camshaft clamp -T10494- must be attached to camshaft

housing.
NOTICE
Risk of damage to valve gear caused by axial movement of the
camshafts.
– Never move camshafts in axial direction when turning them.
• Locking pin - T10340- screwed into cylinder block as far as

stop and tightened to 30 Nm.
• Crankshaft has been turned in direction of engine rotation until
it rests against locking pin - T10340- = “TDC” position.
– Check, if all roller rocker fingers are seated properly on valve

stem end and if their clipped into the respective compensation
element.
– Fit seal with oil strainer -2- into cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
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spec
t to the co
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cial p
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90
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
AG. Volkswagen AG d
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olksw not
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h eo
aut 4-cylinder injection engine (1.4 l, 4V, ra
c
EA211, turbocharger) - Edition 07.2019
ss
ce
le
– Screw 2 studs -items 2, 4- (e.g. -T10288/4- ) into cylinder head.
un
pt
an
d
itte
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– Carefully lower camshaft housing -3- vertically onto studs in
rm
ab
cylinder head.
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Note
spec
es, in part or in w
t to the co
Ensure that camshaft housing is not canted.
– Tighten bolts for camshaft housing ⇒ page 83 .
rrectness of i
l purpos

– Install high-pressure pipe ⇒ page 294 .
nform
ercia

m
a
com
tion in
– Install ignition coils ⇒ page 315 .
r
te o
thi
– Install coolant pump ⇒ page 212 .
s
iva
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rp
cum
– Restore electrical connections and observe routing ⇒ Current
fo
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flow diagrams, Electrical fault finding and Fitting locations.

t.
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Cop py
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Risk of damage to engine
rig
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Avoid damage to valves and piston crowns after working on valve
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gear.
AG.
♦ Turn the engine carefully at least 2 rotations to ensure that

none of the valves make contact when the starter is operated.
Torque settings
♦ ⇒ “1.2.2 Assembly overview - camshaft housing, vehicles with
1.5 Checking compression

♦ Spark plug socket - 3122 B-
1. Cylinder head 91
Jetta 2015 ➤
♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30°C.
• Battery voltage at least 12.5 V. AG. Volkswagen AG d
agen oes
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– Remove fuse for fuel pump control unit ed from fuse holder. Fuse
b ara
nte
is
assignment ⇒ Current flow diagrams,
thor Electrical fault finding eo
and Fitting locations s au ra
c
s
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un
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Note
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Removing fuse interrupts voltage supply for fuel pump control
wit
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unit.
h re
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spec
– Start engine and run it until it turns off.
t to the co
– Switch off ignition.
rrectness o
cial p
f inform
mer
atio
om
n
c
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sd
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Pull off connector -2- and unscrew bolt -1-.

– Pull out ignition coils with output stages.
– Unscrew spark plugs using spark plug socket and extension -
3122 B- .
– Check compression pressure using compression tester -
V.A.G 1763- ; refer to ⇒ Operating instructions .
– Have a second mechanic press down accelerator pedal com‐
pletely and simultaneously operate starter until pressure no
longer increases on tester display.
– Repeat procedure on each cylinder.
Compression pressures agen
AG. Volkswagen AG d bar
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Maximum difference between cylinders s 3.0
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Assembly is carried out in reverse sequence; note the following:
ility
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– Install spark plugs.
h re
ole,
– Install ignition coils with output stages ⇒ page 315 .
spec
t to the co
– Entries will have been made in the event memory of the engine
control unit because connectors were separated and the en‐
gine was started.
rrectne
– Carry out function Generate readiness code in Guided
Functions mode of ⇒ Vehicle diagnostic tester. ss o
Torque settings
cial p
f inform
♦ ⇒ “1.1 Assembly overview - ignition system”, page 314

mer
atio
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or
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t.
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Cop py
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rig ht
py by
co Vo
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Prote AG.
1. Cylinder head 93
Jetta 2015 ➤ agen
AG. Volkswagen AG d
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4-cylinder injection
by
Vol engine (1.4 l, 4V, EA211, not
gturbocharger)
u - Edition 07.2019
ara
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th or
au
2 Toothed belt drive
ac
ss
ce
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nl
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⇒ “2.1 Assembly overview - toothed belt cover”, page 94
an
itte
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⇒ “2.2 Assembly overview - toothed belt”, page 95
ility
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⇒ “2.3 Removing and installing toothed belt guard”, page 98
, is n
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hole
⇒ “2.4 Removing and installing toothed belt”, page 99
spec
es, in part or in w
⇒ “2.5 Checking valve timing”, page 109
t to the co
⇒ “2.6 Adjusting valve timing”, page 115
rrectness of i
⇒ “2.7 Removing toothed belt from camshaft”, page 130
l purpos
2.1 Assembly overview - toothed belt cover
nform
ercia
1 - Lower toothed belt guard

m
at
om
ion
⇒ page 99
c
in t
or
his
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2 - Bolt
a
do
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❑ 8 Nm
um
for
en
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t.
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3 - Engine support
Co
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❑ Specified torque and yri
gh by
ht
tightening sequence
op Vo
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⇒ page 24
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Prote AG.
4 - Bolt
tightening sequence
⇒ page 24
5 - Upper toothed belt guard
⇒ page 98
6 - Bolt
❑ 8 Nm

Jetta 2015 ➤
2.2 Assembly overview - toothed belt

⇒ “2.2.1 Assembly overview - toothed belt, vehicles without ad‐
justable exhaust camshaft”, page 95
⇒ “2.2.2 Assembly overview - toothed belt, vehicles with adjust‐
able exhaust camshaft”, page 97
2.2.1 Assembly overview - toothed belt, vehicles without adjustable exhaust cam‐
shaft
1 - Toothed belt
❑ Check for wear
❑ Removing ⇒ page 99
❑ Adjusting valve timing
⇒ page 115
❑ Observe bending radius
⇒ page 101
2 - Bolt
❑ 25 Nm
3 - Tensioning pulley
❑ Removal and installa‐
tion involve removing
engine support
⇒ page 48 . AG. Volkswagen AG d
agen oes
olksw not
4 - Bolt d byV gu
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❑ Renew after removal hor eo
aut ra
❑ Specified torque and ss c
tightening sequence
ce
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un
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⇒ page 148
an
d
itte
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ab
5 - Exhaust camshaft toothed
ility
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belt pulley
wit
is n
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ole,
⇒ page 162
spec
6 - Inlet camshaft toothed belt
t to the co
pulley
❑ With camshaft adjuster
rrectne
camshaft adjuster
⇒ page 145
ss o
cial p
7 - Guide bush
inform
mer
8 - Bolt
atio
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c
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or

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9 - O-ring
p
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❑ Renew if damaged yi
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Co
op py
10 - Plug
. C rig
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rig by
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❑ 20 Nm co Vo
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11 - O-ring
AG.

❑ Captive, supplied with “item 13”
2. Toothed belt drive 95

Jetta 2015 ➤
12 - Spacer sleeve
13 - Idler roller
14 - Bolt
❑ 45 Nm
15 - Crankshaft pulley
❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
❑ Can only be fitted in one position
Plug for “TDC” drilling in cylinder block - specified torque

• Renew O-ring if damaged.
Bolt -arrow- 30 Nm
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Cop py
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Prote AG.

Jetta 2015 ➤
2.2.2 Assembly overview - toothed belt, vehicles with adjustable exhaust cam‐
shaft olks
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rise nte
1 - Toothed belt tho eo
s au ra
c
❑ Check for wear s
ce
le
un
pt
❑ Removing ⇒ page 99
an
d
itte
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❑ Adjusting valve timing
rm
ab
pe
⇒ page 123
ility
ot
wit
❑ Observe bending radius
, is n
h re
⇒ page 106
hole
spec
2 - Bolt
es, in part or in w
t to the co
❑ 25 Nm
3 - Tensioning pulley
rrectness of i
❑ Removal and installa‐
tion involve removing
l purpos
engine support
⇒ page 48 .
nform
ercia
4 - Bolt
m
a
com
t
ion in
r
❑ 8 Nm +45°
te o
thi
s
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5 - Cap
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6 - Bolt
en
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t.
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op
❑ Renew after removal C py
ht. rig
rig ht
❑ Specified torque and py by
co Vo
tightening sequence
by lksw
cted agen
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⇒ page 144
AG.
7 - Exhaust camshaft toothed

belt pulley
camshaft adjuster
⇒ page 149
8 - Guide bush
9 - Inlet camshaft toothed belt
pulley
❑ Removing and installing camshaft adjuster ⇒ page 141
10 - Bolt
11 - O-ring
12 - Plug
❑ 20 Nm
13 - Spacer sleeve
❑ With O-ring
❑ Supplied with “item 14”

Jetta 2015 ➤ agen
AG. Volkswagen AG d
oes
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by V - Edition 07.2019
ol
gu
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ed ran
oris tee
14 - Idler roller au
th or
ac
ss
15 - Bolt
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an
❑ 45 Nm
d
itte
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16 - Crankshaft pulley
ility
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❑ Contact surface between toothed belt pulley and crankshaft must be free from oil
wit
is n
h re
❑ Can only be fitted in one position
ole,
spec
t to the co
Plug for “TDC” drilling in cylinder block - specified torque
• Renew O-ring if damaged.
rrectne
Torque settings
ss o
cial p
f inform
Bolt -arrow- 30 Nm
mer
atio
om
n
c
i
or
n thi
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sd
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cum
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fo
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t.
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op py
2.3 Removing and installing toothed belt
t. C rig
gh ht
yri by
guard
cop Vo
by lksw
cted agen
Prote AG.
⇒ “2.3.1 Removing and installing upper toothed belt guard”, page
98
⇒ “2.3.2 Removing and installing lower toothed belt guard”, page
99
2.3.1 Removing and installing upper toothed

belt guard
Removing
– Detach hoses from retainer -3-.
– Release clips -arrows- and remove upper toothed belt guard
-1-.
Installing
Torque settings

Jetta 2015 ➤
2.3.2 Removing and installing lower toothed

AG. Volkswagen AG d
agen
belt guard yV
olksw oes
not
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Removing horis nte
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t or
au ac
– Remove vibration damper
ss ⇒ page 46 .
ce
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un
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an
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itte
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– Remove lower part of toothed belt guard.
erm
ab
ility
ot p
Installing
wit
is n
h re
ole,
spec
– Install vibration damper ⇒ page 46 .
t to the co
Torque settings
rrectne
ss o
cial p
f
inform
mer
⇒ “2.4.1 Removing and installing toothed belt, vehicles without
atio
m

o
n
c
i
or
n thi
⇒ “2.4.2 Removing and installing toothed belt, vehicles with ad‐
te
sd
va
justable exhaust camshaft”, page 104

i
o
pr
cum
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fo
2.4.1 Removing and installing toothed belt, vehicles without adjustable exhaust
en
ng
t.
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op
camshaft
C py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

Jetta 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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♦ Torque wrench - VAS 6583-
ce
le
un
pt
an
d
itte
♦ Counterhold - T10172- with adapter -T10172/1- and -

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ab
T10172/2-
pe
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♦ Locating bolt - T10340-

wit
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hole

spec
es, in part or in w
♦ Special wrench, 30 mm - T10499-

t to the co
♦ Insert tool - T10500-

rrectness of i
♦ Camshaft clamp - T10494-

l purpos
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
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cted agen
Prote AG.

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ho eo
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nl
pt
du
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itte
♦ Special wrench, 30 mm - T10499A-
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ility
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es, in part or in w
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nf
ercia
orm
m
Removing atio
om
n in
c

or
thi
te
sd
a

iv
o
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rp
cu
o
– Remove vibration damper ⇒ page 46 .

f
en
ng
t.
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op
– Remove lower toothed belt guard ⇒ page 99 . C py
ht. rig
rig ht
by
Before removing toothed belt, mark direction of rotation with chalk copy Vo
by lksw
or felt tipped pen for installation purposes. cted agen
Prote AG.
Bend radius of toothed belt
Note
♦ Risk of damage to toothed belt by bending it excessively. The

toothed belt is made of glass fibre fabric which will be damaged
if it is bent excessively.
♦ Never bend toothed belt to a radius less than r = 25 mm.
• The bend radius -r- on the toothed belt -2- should therefore not
be below 25 mm (approx. half the diameter of gear -1- on
crankshaft).
– Remove toothed belt.
NOTICE

Jetta 2015 ➤

Installing
• Renew O-ring of plug if damaged.
– Check “TDC” position of camshaft and crankshaft:
• Camshaft clamp -T10494- must be attached to camshaft

housing.
Note
♦ Risk of damage to camshaft caused by improper handling.

♦ Never use the camshaft clamp for counter holding.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
• Locking pin - T10340- screwed into cylinder block as far as s
ce
e

nl
pt
du
an
itte
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erm
ab

ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Renew bolts -1- and -2- for camshaft pulleys and screw them
in loosely ⇒ page 141 .
nf
ercia
orm
• It should just be possible to turn camshaft pulleys on cam‐

m
atio
m
shafts but no rocking is permissible.

o
n in
or c
thi
te
sd
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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.

Jetta 2015 ➤
• The sheet-metal tab -arrow- of the tensioning roller must en‐

gage in the cast notch in the cylinder head.

• Contact surface between poly V-belt pulley and crankshaft
nal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Bend radius of toothed belt rised
nte
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Note
ce
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d
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rm
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pe
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wit
, is n
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hole
spec
es, in part or in w
t to the co
crankshaft).
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
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by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Fit toothed belt -1- on crankshaft pulley -2- first from below.
– Install lower toothed belt guard ⇒ page 99 .
AG. Volkswagen AG d
agen oes
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Fit toothed belt in prescribed sequence: by Vol
gu
ara
d
ise nte
– Pull toothed belt upwards and fit on idler pulley
thor
-1-, tensioning eo
roller -2- and camshaft toothed belt pulleys
ss a -3- and -4-.
u ra
c
ce
e
– Fit toothed belt and adjust valve timing ⇒ page 115 .

nl
pt
du
an
itte
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Further assembly is carried out in the reverse order of removal.
erm
ab
ility
ot p
Torque settings
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ ⇒ “2.2 Assembly overview - toothed belt”, page 95
rrectness of i
que”“ , page 98
l purpos
♦ ⇒ “1.2.1 Assembly overview - camshaft housing, vehicles with‐

out adjustable exhaust camshaft”, page 80
nform
ercia
♦ ⇒ “3.1 Assembly overview - crankcase breather system”, page

183
m
at
om
io
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
n
c
in t
or
page 206
his
ate
do
riv

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cum
for
en
g

n
t.
yi Co
Cop py
t. rig
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yri
p by
co Vo
by lksw
noise insulation Prote
cted AG.
agen
2.4.2 Removing and installing toothed belt, vehicles with adjustable exhaust cam‐
shaft

Jetta 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
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
♦ Torque wrench - VAS 6583- t. C rig
gh ht
pyri by
♦ Counterhold - T10172- with adapter -T10172/1-
o Vo
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
Removing
– Remove vibration damper ⇒ page 46 .
– Remove lower toothed belt guard ⇒ page 99 .
AG. Volkswagen AG d
agen oes
Before removing toothed belt, mark direction ofyrotation
Vol
ksw with chalk not
gu
or felt tipped pen for installation purposes.ised b ara
nte
r
ho eo
Bend radius of toothed belt aut ra
c
ss
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p

wit

, is n
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hole
spec

es, in part or in w
t to the co
rrectness of i
crankshaft).
l purpos
– Remove toothed belt.

nf
ercia
NOTICE
orm
m

atio
om
n in

or c
thi
te
sd
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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
106
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Jetta 2015 ➤

Installing
– Check “TDC” position of camshaft and crankshaft
⇒ page 109 .
• Camshaft clamp - T10494- fitted on camshaft housing.

AG. Volkswagen AG d
agen oes
olksw not
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b
Note rise
d ara
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au ra
♦ Risk of damage to camshaft
ss caused by improper handling. c
ce
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nl
pt
♦ Never use the camshaft clamp for counter holding.
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Renew bolts -1- and -2- for camshaft pulleys and screw them Cop py
in loosely.
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
e d
Jetta 2015 ➤ oris nte
eo
th
s au turbocharger) - Edition 07.2019 ra
c
s
ce
e
nl
pt
du
an
itte
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
orm
m
atio
om
n in
or c
thi
te
sd
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rp
cu
o
m
f
en
ng
t.
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Co
Cop py
ht. rig
• The contact surface between vibration damper and crankshaft rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
nal.
Note

crankshaft).

Jetta 2015 ➤
– Fit toothed belt -1- on crankshaft pulley -2- first from below.
– Install lower toothed belt guard ⇒ page 99 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
Fit toothed belt in prescribed sequence: le
un
pt
an
d
itte
y li
– Pull toothed belt upwards and fit on idler pulley -1-, tensioning
erm
ab
roller -2- and camshaft toothed belt pulleys -3- and -4-.
ility
ot p
wit
is n
– Adjust valve timing ⇒ page 123 .
h re
ole,
spec
t to the co
Torque settings
rrectne
ss o
cial p
f
inform
que”“ , page 98
mer
atio
om
n
c
i
or
n thi
te
sd
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r
183
p
cum
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t.
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op
page 206 C py
ht. rig
rig ht
py by
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 236 co Vo
by lksw
cted agen
Prote
AG.
2.5 Checking valve timing


Jetta 2015 ➤
♦ Socket T 30 - T10405-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss 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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
Note
♦ This procedure can also be used to set the engine to “TDC

position for cylinder no. 1”.
♦ The valve timing is checked with camshaft clamp - T10494- .
Procedure
sulation .
– Remove air pipe ⇒ page 257 .
– Press release tabs and disconnect hose -1- for activated char‐
coal filter.
– Unscrew bolts -arrows- and remove crankcase breather hose.
– Remove connection for turbocharger ⇒ page 239 .
– Release and pull off connector on ignition coil 4 with output
stage - N292- ⇒ Item 18 (page 260) .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
– Lay wiring harness to one side -arrows-. aut ra
c
ss
– Unscrew bolts -1, 3- and remove cover -2- for toothed belt for
ce
le
un
pt
coolant pump.
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
– Unscrew bolts -arrows- and detach sealing cap -1-.

nform
ercia
Note
m
a
com
tion in
Risk of chemical damage to the coolant pump gasket caused by

r
te o
oil entering between the coolant pump and the cylinder head.
thi
s
iva
do
r
rp
cum
– Cover coolant pump with a cloth to collect any escaping oil.

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
Rotate crankshaft to “TDC” as follows:

– Remove ignition coil 1 with output stage - N70- and cylinder 1
spark plug ⇒ page 314 .
– Insert a screwdriver with a shaft length of at least 250 mm into
spark plug hole so that it contact piston crown.
– Turn crankshaft in direction of engine rotation until piston in
cylinder 1 is at “BDC”.
The screwdriver moves in the -direction of the arrow-.
– Turn crankshaft further in direction of engine rotation until

screwdriver has moved -30 mm- in -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
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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
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Unscrew plug for “TDC” hole in cylinder block.

– Screw locking pin - T10340- into cylinder block as far as stopn AG. Volkswagen AG do
and tighten to 30 Nm. olks
wage es n
o V t gu
by ara
– Rotate crankshaft in normal direction of rotationrisas
ed far as stop. nte
tho eo
• The locking pin now rests against the crank
ss
auweb. ra
c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
Locking pin - T10340- locks crankshaft in direction of engine ro‐
wit
, is n
tation only.
h re
hole
spec
es, in part or in w
t to the co
• If locking pin - T10340- cannot be screwed in as far as stop,
this indicates that crankshaft is not in the correct position!
rrectness of i
• In this case, proceed as follows:
l purpos
• Unscrew locking pin.

• Turn crankshaft 90° in direction of rotation of engine.
nf
ercia
or
• Screw locking pin - T10340- into cylinder block as far as stop
m
m
atio
m
and tighten to 30 Nm.

o
n in
or c
• Turn crankshaft in direction of engine rotation as far as stop.
thi
te
sd
iva
o
r
rp
cu
• The asymmetrically positioned grooves on gearbox end of
o
m
f
en
ng
both camshafts -top arrows- must now be above the horizontal

t.
yi Co
centre line. Cop py
t. rig
gh ht
yri
• Grooves on exhaust camshaft -A- can be accessed through p by
o Vo
by c lksw
recesses -arrows- in toothed belt pulley for coolant pump. Prote
cted AG.
agen
• On inlet camshaft -E-, grooves -arrows- are above horizontal

camshaft centre line.
A - Exhaust camshaft
E - Inlet camshaft
– If camshafts are not positioned as described, unscrew locking
pin - T10340- , turn crankshaft one rotation further and return
to “TDC” position.
Note
♦ The camshaft clamp - T10494- must slide into position easily.

♦ Do not knock camshaft clamp into place with any kind of tool.
If the camshaft clamp - T10494- does not easily slide into position:

Jetta 2015 ➤
Vehicles with 2 camshaft adjusters:

– Use the assembly tool - T10487- to push on toothed belt in
Vehicles with one camshaft adjuster:

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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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
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.

Jetta 2015 ➤

– Insert camshaft clamp - T10494- as far as stop into camshaft.
– Tighten bolts -arrow- by hand.
If camshaft clamp cannot be fitted:
If camshaft clamp can be fitted:
– Valve timing is correct.
• After completing work, check that locking pin - T10340- and
camshaft clamp -T10494- have been removed.
Torque settings
que”“ , page 98
adjustable exhaust camshaft”, page 82 gen AG
. Volkswagen AG
a does
lksw not
♦ ⇒ “3.1 Assembly overview - crankcase breather
db
yV
o
system”, page gu
ara
183 o
ir se nte
h eo
ut ra
♦ ⇒ “2.1 Assembly overview - coolant
ss
a pump, thermostat”, c
page 206
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
2.6 Adjusting valve timing

wit
is n
h re
ole,
⇒ “2.6.1 Checking valve timing, vehicles without adjustable ex‐ spec

haust camshaft”, page 115 t to the co
⇒ “2.6.2 Checking valve timing, vehicles without adjustable ex‐

haust camshaft”, page 123
rrectne
2.6.1 Checking valve timing, vehicles without adjustable exhaust camshaft

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


Jetta 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
♦ Special wrench, 30 mm - sT10499A-
au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Procedure
nform
ercia

m
at
om
ion
c
Adjusting valve timing in t

or
his
ate

do
priv
cum
or

f
en
ng
t.
yi Co
op
– Check “TDC” position of camshaft and crankshaft: C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤

NOTICE
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
Note

crankshaft).
Fit toothed belt in prescribed sequence:

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
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Using special wrench, 30 mm - T10499A- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the right
of adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
Note
♦ Torque wrench - VAS 6583- must be used for tightening.

♦ When setting the specified torque on the torque wrench - VAS
6583- , the length indicated on the insert tool - T10500- must
be entered in the torque wrench.
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.

– To do this, use insert tool - T10500- with torque wrench - VAS
6583- .
Note
♦ Turning the engine further or running the engine may lead to

slight differences in the position of the adjustment indicator
-3- in relation to the adjustment window. The deviations do not
affect the toothed belt tension or the timing.
♦ The securing bolts must not be tightened to the final specified
torque (turning further angle) until the valve timings have been
checked and are OK.
– Tighten securing bolts for camshaft adjuster to specified pre‐

tightening torque ⇒ page 148 . . Volkswagen AG d
gen AG a oes
ksw not
y Vol gu
NOTICE ed
b ara
nte
oris eo
h
Risk of damage
by improperau to camshaft caused
t
handling. ra
c
ss
– Never use the camshaft clamp for counter holding.
ce
le
un
pt
an
d
itte
y li
erm
ab
– Unscrew locking pin - T10340- .

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.

Jetta 2015 ➤
– Remove bolt -arrow- and detach camshaft clamp - T10494- .
Checking timing after it has been set

– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw locking pin - T10340- into cylinder block as far as stop
and tighten to 30 Nm. en AG. Volkswagen AG
ag does
lksw n
– Rotate crankshaft
db
y V further in direction of engine trotation
o o g
ua as far
as stop. orise ran
te
h eo
ut ra
• The locking
ss
a pin now rests against the crank web. c
ce
le
un
pt
an
d
itte
Note
y li
erm
ab
ility
ot p
♦ Locking pin - T10340- locks crankshaft in direction of engine

wit
is n
rotation only.
h re
ole,
spec
♦ It should be possible to insert the camshaft clamp - T10494-

easily.
t to the co
rrectne
ss

o
cial p
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Jettaaut2015 ➤ ra
c
s
4-cylinder
s injection engine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
ce
le
un
pt
an
d
itte
– Insert camshaft clamp -T10494- as far as stop into camshaft.
y li
rm
ab
pe
– Tighten bolt -arrow- by hand.
ility
ot
wit
, is n
If it is not possible to insert the camshaft clamp - T10494- , the
h re
hole
valve timing is not correct.
spec
es, in part or in w
– Repeat adjustment of valve timing ⇒ page 117 .
t to the co
rrectness of i
l purpos
nform
ercia
If it is possible to insert the camshaft clamp - T10494- , the valve

m
a
timing is correct.
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove bolt -arrow- and detach camshaft clamp -T10494- .

Jetta 2015 ➤
– Tighten securing bolts -1- and -2- to specified torque

⇒ page 148 .
♦ After completing work, check that locking pin - T10340- and
camshaft clamp - T10494- have been removed.
Torque settings
que”“ , page 98
♦ ⇒ “1.2.1 Assembly overview - camshaft housing, vehicles with‐
out adjustable exhaust camshaft”, page 80
183
2.6.2 Checking valve timing, vehicles without adjustable exhaust camshaft

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
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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.

Jetta 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
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
♦ Torque wrench - VAS 6583- by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
Procedure
Adjusting valve timing
• Renew bolts that are tightened
agen
AG. Volkswwith turning
agen AG do further angle.
w es n
olks ot g
• Renew O-ring
d b of plug if damaged.
yV ua
ran
e
ris te
– Check
ut “TDC” position of camshaft and
ho crankshaft: e or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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.

Jetta 2015 ➤

NOTICE
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
• The sheet-metal tab -arrow- of the tensioning roller must
ss en‐ 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
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.

Jetta 2015 ➤
Note

Volkswa
♦ Never bend toothed belt to a radius
swa less than r = 25 mm.
gen AG
. gen AG
does
olk not
V gu
d by ar
• The bend radius -r- on rise toothed belt -2- should therefore not ante
the
ho eo
be below 25 mm (approx.
au
t
half the diameter of gear -1- on ra
c
s
crankshaft). s
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
Fit toothed belt in prescribed sequence:
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.

Jetta 2015 ➤
– Using special wrench, 30 mm - T10499A- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to the right
of adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
AG. Volkswagen AG d
agen oes
Note olksw not
V gu
d by ara
ise nte
r
♦ Torque wrench - VAS
aut 6583- must be used for tightening.
ho eo
ra
ss c
♦ When setting the specified torque on the torque wrench - VAS
ce
e
nl
6583- , the length indicated on the insert tool - T10500- must
pt
du
an
be entered in the torque wrench.
itte
y li
erm
ab
ility
ot p
– Hold eccentric in that position and tighten bolt -1- to 25 Nm.
wit
, is n
h re
– To do this, use insert tool - T10500- with torque wrench - VAS
hole
spec
6583- .
es, in part or in w
t to the co
Note
rrectness of i
♦ Turning the engine further or running the engine may lead to
l purpos
slight differences in the position of the adjustment indicator

-3- in relation to the adjustment window. The deviations do not
affect the toothed belt tension or the timing.
nf
ercia
or
♦ The securing bolts must not be tightened to the final specified
m
m
torque (turning further angle) until the valve timings have been atio
om
n in
checked and are OK.

or c
thi
te
sd
iva
– Tighten securing bolts for camshaft adjuster to specified pre‐

o
r
rp
cu
o
tightening torque ⇒ page 144 .

m
f
en
ng
t.
yi Co
op py
NOTICE t. C rig
gh ht
pyri by
Risk of damage to camshaft caused by improper handling.
o Vo
by c lksw
cted agen
Prote
AG.

Jetta 2015 ➤
– Remove bolt -arrow- and detach camshaft clamp - T10494- .
Checking timing after it has been set

– Turn crankshaft 2 turns in direction of rotation of engine.
– Screw locking pin - T10340- into cylinder block as far as stop
and tighten to 30 Nm. en AG. V
olkswagen AG
ag does
lksw not
– Rotate crankshaft further in direction of engine
db
y V rotation as far
o gu
ara
as stop. or
ise nte
h eo
ut ra
• The locking pin now rests against the
ss crank web.
a c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ Locking pin - T10340- locks crankshaft in direction of engine
wit
, is n
rotation only.
h re
hole
spec
♦ It should be possible to insert the camshaft clamp - T10494-
es, in part or in w
easily.
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert camshaft clamp -T10494- as far as stop into camshaft.

– Tighten bolt -arrow- by hand.
If it is not possible to insert the camshaft clamp - T10494- , the
valve timing is not correct.
– Repeat adjustment of valve timing ⇒ page 125 .

Jetta 2015 ➤
If it is possible to insert the camshaft clamp - T10494- , the valve

timing is correct.
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
– Remove bolt -arrow- and detach camshaft clamp -T10494- .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Tighten securing bolts -1- and -2- to specified torque
atio
m
⇒ page 144 .
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
♦ After completing work, check that locking pin - T10340- and
o
m
f
camshaft clamp - T10494- have been removed.

en
ng
t.
yi Co
op py
Further assembly is carried out in the reverse order of removal. . C rig
ht ht
rig by
py
Torque settings
co Vo
by lksw
cted agen
Prote AG.
que”“ , page 98
183
2.7 Removing toothed belt from camshaft

Jetta 2015 ➤

equipment required
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.

♦ Counterhold - T10172- with adapter -T10172/1- and -
T10172/2-

Jetta 2015 ➤
Removing
– Remove noise insulation ⇒ General body repairs, exterior; agen
AG. Volkswagen AG d
oes
Rep. gr. 66 ; Noise insulation; Assembly overview - noise yV
oin‐
lksw not
gu
sulation . ised b ara
n r tee
ho
– Remove resonator for intake air ⇒ page 272 . s aut or
ac
s
ce
e
nl
pt
du
an
itte
– Remove connection for turbocharger ⇒ page 239 .
y li
erm
ab
ility
– Release and pull off electrical connector -1-.
ot p
wit
, is n
– Lay aside wiring -2- on coolant expansion tank.

h re
hole
spec
– Using a screwdriver, release fasteners -arrow- and move cool‐
es, in part or in w
ant expansion tank to one side.

t to the co
– Disconnect plug-in connectors from fuel hose and from hose

to activated charcoal filter.
rrectness of i
– Remove upper toothed belt guard ⇒ page 98 .

l purpos

nf
ercia
NOTICE
orm
m
atio

om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
– If the toothed belt is to be reinstalled, mark direction of rotation

with chalk or felt tipped pen for installation purposes.
– Fit special wrench, 30 mm
wage
n A-GT10499A-
. Volkswagenon
AG deccentric
oes adjuster
-2- of tensioningy Vroller.
olks not
gu b ara
ed
– Loosen bolt
ho -1- with tool insert - T10500- .
ris nte
e
t or
au a
– Releasess tensioning roller on eccentric adjuster -2- using spe‐
c
cial wrench, 30 mm - T10499A- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
Note
om
ion
c
in t
or
♦ Risk of damage to toothed belt by bending it excessively. The his

ate
do
riv

p
cum
for
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
crankshaft).
– Remove toothed belt from camshaft pulleys.
NOTICE
Installing
Torque settings
que”“ , page 98
183

Jetta 2015 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 134
⇒ “3.2 Measuring axial play of camshaft”, page 135
⇒ “3.3 Removing and installing camshaft oil seal”, page 136
⇒ “3.4 Removing and installing camshaft adjuster”, page 141
⇒ “3.5 Removing and installing camshaft control valve 1 N205 ”,
page 153
⇒ “3.6 Removing and installing exhaust camshaft control valve 1
N318 ”, page 154
⇒ “3.7 Removing and installing valve stem seals”, page 154
⇒ “3.8 Removing and installing toothed belt pulley”, page 162
3.1 Assembly overview - valve gear

olkswagen AG
en AG. V
1 - Inlet valve ksw
ag does
not
y Vol gu
❑ Do not rework. Only lap‐ ised b ara
nte
ping in is permitted. uthor eo
a ra
❑ Valve dimensions ss c
⇒ page 165
ce
le
un
pt
an
d
❑ Checking valve guides

itte
y li
⇒ page 164
erm
ab
ility
ot p
2 - Outlet valve
wit
is n
h re
❑ Do not rework. Only lap‐
ole,
spec
ping in is permitted.
❑ Valve dimensions t to the co

⇒ page 165
❑ Checking valve guides
rrectne
⇒ page 164
3 - Cylinder head
ss o
4 - Valve stem seal

cial p
f inform

mer
⇒ page 154
atio
om
5 - Valve springs
c
i
or
n thi
e
t
sd
va
⇒ page 135
i
o
pr
cum
r
fo
en
ng
6 - Valve spring plate

t.
yi Co
Cop py
7 - Valve cotters
t. rig
gh ht
pyri by
Vo
o
8 - Roller rocker fingers by c lksw
cted agen
Prote AG.
⇒ page 87
❑ Mark installation posi‐
tion for re-installation.
❑ Check roller bearing for
ease of movement.
❑ Lubricate contact surfa‐
ces before installing.
9 - Retaining clip
❑ For hydraulic compensation element.

Jetta 2015 ➤
AG. Volkswagen AG d
10 - Hydraulic compensation wagelement
en oes
Volks not
gu
❑ Do not interchange
ed
by ara
nte
ris
❑ Oil contact
ut surface
ho eo
ra
a c
ss
ce
e
nl
pt
du
an
Installation position of valve spring
itte
y li
erm
ab
• The end with smaller diameter -a- must face towards valve
ility
ot p
spring plate.
wit
, is n
h re
• The end with larger diameter -b- must face towards cylinder
hole
spec
head.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
3.2 Measuring axial play of camshaft
rm
m
atio
om
n in
or c
thi
te
♦ Universal dial gauge holder - VW 387-
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.
♦ Dial gauge - VAS 6079-
3. Valve gear 135

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
lksw not
Procedure byV
o gu
ara
ed
is nte
– Remove camshaft housing ⇒ page 87 . uth or eo
a ra
s c
– Secure dial gauge - VAS 6079- with universal dial gauge s
ce
e
bracket - VW 387- to camshaft housing as shown in illustration.
nl
pt
du
an
itte
y li
– Press camshaft against dial gauge by hand.
erm
ab
ility
ot p
– Set dial gauge to “0”.
wit
, is n
h re
– Press camshaft away from dial gauge and read off value: hole
spec
Axial clearance:
es, in part or in w
t to the co
• Wear limit: 0.25 mm.
rrectness of i
3.3 Removing and installing camshaft oil
seal
l purpos
⇒ “3.3.1 Removing and installing camshaft oil seal for inlet cam‐
nform
ercia
shaft, belt pulley end”, page 136

m
at
⇒ “3.3.2 Removing and installing exhaust camshaft oil seal, pulley
om
io
end”, page 138
n
c
in t
or
his
e
⇒ “3.3.3 Removing and installing exhaust camshaft oil seal, gear‐

at
do
riv
box end”, page 139

p
cum
for
en
g
3.3.1 Removing and installing camshaft oil

n
t.
yi Co
op py
seal for inlet camshaft, belt pulley end
. C rig
ht ht
rig by
copy Vo
by lksw
Special tools and workshop equipment required Prote
cted AG.
agen
♦ Assembly tool - T10478 B-

AG. Volkswagen AG d
agen
Volksw
oes
not Jetta 2015 ➤
by gu
ised 4-cylinder injection engine (1.4
ara l, 4V,
nte EA211, turbocharger) - Edition 07.2019
or eo
h
ut ra
Removing
ss a c
ce
le
un
– Removing camshaft adjuster ⇒ page 141 .
pt
an
d
itte
y li
– Use extractor hook -T20143/1- to lever out seal -1-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
Installing
s o
cial p
f i
nform
mer
– Fit seal -1- over fitting sleeve -T10478/3- onto guide sleeve -
atio
m
T10478/2- .
o
n
c
i
or
n thi
te
sd
iva
o
r
– Separate fitting sleeve and guide sleeve.

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Draw in seal to stop using thrust piece -T10478/1A- and »old«

bolt -1- for camshaft pulley.
– Install camshaft adjuster ⇒ page 141 .
3. Valve gear 137

Jetta 2015 ➤
3.3.2 Removing and installing exhaust cam‐

shaft oil seal, pulley end
♦ Assembly tool - T10478 B-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Removing, vehicles with adjustable exhaust camshaft

t.
yi Co
Cop py
t.
– Remove camshaft adjuster for exhaust camshaft
rig
gh ht
yri by
⇒ page 149 . op Vo
by c lksw
cted agen
Prote
Removing, vehicles without adjustable exhaust camshaft
AG.
– Remove toothed belt pulley for exhaust camshaft

⇒ page 162 .
– Use extractor hook -T20143/1- to lever out seal -1-.

Jetta 2015 ➤
Installing
T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- to camshaft.

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
– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far as

t to the co
stop.
Installing, vehicles with adjustable exhaust camshaft
rrectness of i
– Install camshaft adjuster for exhaust camshaft ⇒ page 149 .

l purpos
Installing, vehicles without adjustable exhaust camshaft

nform
ercia
– Install toothed belt pulley for exhaust camshaft ⇒ page 162 .

m
Continued for all

a
com
tion in
– Installing engine support ⇒ page 48 .

r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
3.3.3 Removing and installing exhaust cam‐

n
t.
yi Co
op py
shaft oil seal, gearbox end
t. C rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
3. Valve gear 139

Jetta 2015 ➤
♦ Assembly tool - T10479 A-
Removing
– Remove toothed belt pulley for coolant pump ⇒ page 219 .
Note
Risk of chemical damage to the coolant pump gasket caused by

oil entering between the coolant pump and the cylinder head.
– Cover coolant pump with a cloth.

– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out seal.
Installing
G. Volkswagen AG d
– Remove any burrs in the outer area of the grooves in the ex‐ lksw
agen
A
oes
not
haust camshaft -arrows- using fine sandpaper (220–1000 P).db
yV
o gu
ara
e nte
ris
• Do not lubricate new seal. utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
T10479/2- .
rrectness of i

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

Jetta 2015 ➤
– Fit guide sleeve -T10479/2- with oil seal -2- centrally to cam‐
shaft.
– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Push seal onto camshaft and unbolt guide sleeve.
– Draw in seal -2- to stop using thrust piece -T10479/1- and bolt
-1- for toothed belt pulley for coolant pump.
– Install toothed belt pulley for coolant pump ⇒ page 219 .
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
3.4 Removing and installing camshaft ad‐

hole
spec
juster
es, in part or in w
t to the co
⇒ “3.4.1 Removing and installing inlet camshaft adjuster, vehicles

with adjustable exhaust camshaft”, page 141
rrectness of i
⇒ “3.4.2 Removing and installing inlet camshaft adjuster, vehicles

l purpos
without adjustable exhaust camshaft”, page 145

⇒ “3.4.3 Removing and installing camshaft adjuster for exhaust
nf
ercia
camshaft”, page 149

orm
m
3.4.1 Removing and installing inlet camshaft

atio
om
n in
c
adjuster, vehicles with adjustable ex‐

or
thi
te
haust camshaft
sd
iva
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Valve gear 141

Jetta 2015 ➤
♦ Counter-hold tool - T10172A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
♦ Counter-hold tool - T10554- s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Preparing tools
nf
ercia
– Bolt on counter-hold tool - T10172- and counter-hold tool - orm

m
atio
T10554/1- using knurled screws - T10554/2- -arrows-.
om
n in
c
Removing
or
thi
te
sd
iva
– Place a cloth beneath camshaft adjuster and tensioning roller

o
r
rp
cu
to catch escaping engine oil.

o
m
f
en
ng
t.
yi
– Contact points between toothed belt and components such as
Co
Cop py
camshaft pulleys, crankshaft pulley, tensioning roller and idler ht. rig
rig ht
roller must be kept free of oil.
py by
co Vo
by lksw
cted agen
Prote AG.
Fitting counter-hold tool - T10554-

• Pins -1- and -2- are located at different distances to the coun‐
ter-hold tool - T10554- .
• The counter-hold tool - T10554- can be inserted in only one
position.
NOTICE

Jetta 2015 ➤
– Fit counter-hold tool - T10554- with counter-hold tool -

T10172- to camshaft adjuster -1- as shown in illustration.
– The pins must be inserted properly into holes -arrows-.
– Secure camshaft against turning with counterhold - T10554-
and counterhold - T10172- .
– Unscrew plug -1- on inlet camshaft adjuster.
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
T10172- again, to loosen securing bolt -1- of camshaft adjust‐

erm
ab
er.
ility
ot p
wit
is n
– Loosen bolt -1- of camshaft adjuster -2-.

h re
ole,
– Loosen securing bolt of exhaust camshaft adjuster

spec
⇒ page 149 .
t to the co
– Unscrew securing bolt -1- of camshaft adjuster, and remove

camshaft adjuster -2-.
rrectne
Installing
• Camshafts are located in “TDC” position.
ss o
cial p
• The camshaft pulleys are properly aligned with each other.

inform
mer
• Crankshaft is in “TDC position”.

atio
om
• Guide sleeve of camshaft adjuster must be fitted to camshaft

n
c
i
or
prior to installation.
thi
te
sd
iva

o
pr
cum
r
fo
en
ng
– Renew O-ring of plug if damaged.

t.
yi Co
Cop py
t. rig
gh ht
– Install camshaft adjuster.
yri
p by
co Vo
by lksw
cted
– Renew bolts -1- and -2- for camshaft adjusters, and screw
agen
Prote AG.
them in loosely.
NOTICE
3. Valve gear 143

Jetta 2015 ➤
Pre-tightening
– Hold inlet camshaft in position using counter-hold tool -
T10554- and counter-hold tool - T10172- .
– Pre-tighten bolt -1- to specified pre-tightening torque in two
stages.
– The assistance of a second mechanic is required for counter
holding.
Stage Securing bolt for camshaft Specified torque
adjuster, inlet camshaft agen
AG. Volkswagen AG d
oes
olksw not
1 -1- 15 Nm ed by
V gu
ara
ris nte
2 -1- 50 Nm ut
ho eo
ra
s a c
s
ce
le
– Hold exhaust camshaft in position using counterhold tool -
un
pt
an
T10554- and counterhold tool - T10172- . d
itte
y li
erm
ab
ility
ot p
stages.
wit
is n
h re
ole,
spec
adjuster, exhaust camshaft
t to the co
1 -1- 15 Nm
2 -1- 50 Nm
rrectness o
cial p
f i
Tightening to final specified torque
nform
mer
– Tighten bolt -1- for camshaft adjuster to final specified torque.
atio
om
n
c
Securing bolt for camshaft ad‐ Angle to turn bolts
i
or
n thi
e
juster, inlet camshaft

t
sd
iva
o
pr
c
-1- 135°
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Tighten securing bolt for exhaust camshaft adjuster -1- to final

specified torque.
juster, exhaust camshaft
-1- 135°

Jetta 2015 ➤

– Screw in plug -1-, and tighten it to specified torque.
Plug for camshaft adjuster Specified torque
-1- 20 Nm
Assembling
Assemble in reverse order of dismantling.
Torque settings
♦ ⇒ “3.1 Assembly overview - air filter housing”, page 270
que”“ , page 98
3.4.2 Removing and installing inlet camshaft Volks
wage es n
ot g
adjuster, vehicles without adjustable by
ex‐
ua
ed ran
oris tee
haust camshaft sa
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3. Valve gear 145

Jetta 2015 ➤
Preparing tools
– Bolt on counter-hold tool - T10172- and counter-hold tool -
T10554/1- using knurled screws - T10554/2- -arrows-.
Removing
camshaft pulleys, crankshaft pulley, tensioning roller and idler

gen A n AG G. Volkswage
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spec
T10172- to camshaft adjuster -1- as shown in illustration.

t to the co
– The pins must be inserted properly into holes -arrows-.

– Secure camshaft against turning with counterhold - T10554-
rrectne
and counterhold - T10172- .

ss o
cial p
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Jetta 2015 ➤
– Unscrew plug -1- on inlet camshaft adjuster.

T10172- again, to loosen securing bolt -1- of camshaft adjust‐
er.
– Loosen bolt -1- of camshaft adjuster -2-.
– Loosen securing bolt of exhaust camshaft pulley
⇒ page 149 .
– Unscrew securing bolt -1- of camshaft adjuster, and remove
camshaft adjuster -2-.
Installing
– Renew O-ring of plug if damaged.
AG. Volkswagen AG d
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– Install camshaft adjuster.
by Vol
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d
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– Renew bolt -1- thor
for camshaft adjuster of inlet camshaft, and eo
screw it inssloosely.
au ra
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– Renew bolt -2- for exhaust camshaft pulley, and screw it in

un
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loosely.
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spec
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147
AG.
3. Valve gear
Jetta 2015 ➤
Pre-tightening
– Before pre-tightening, unscrew locking pin - T10340- .
stages.
holding.
adjuster, inlet camshaft
1 -1- 15 Nm
2 -1- 50 Nm

T10172- and adapter - T10172/1- .
stages.
Stage Securing bolt for toothed Specified torque
belt pulley
1 -1- 15 Nm
2 -1- 50 Nm
Tightening to final specified torque

– Tighten bolt -1- for camshaft adjuster to final specified torque.
juster, inlet camshaft AG. Volkswagen AG d
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– Tighten securing bolt for exhaust camshaft pulley to final

h re
hole
specified torque.
spec
es, in part or in w
t to the co
Securing bolt for toothed belt pul‐ Angle to turn bolts

ley
-1- 90°
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Jetta 2015 ➤

-1- 20 Nm
Assembling
Assemble in reverse order of dismantling.
Torque settings
que”“ , page 98
3.4.3 Removing and installing camshaft ad‐

juster for exhaust camshaft
lkswage es n
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3. Valve gear 149

Jetta 2015 ➤
Preparing tools
– Bolt counter-hold tool - T10172- and counter-hold tool -
T10554/1- together using knurled screws - T10554/2-
-arrows-.
Removing
camshaft pulleys, crankshaft pulley, tensioning roller and idler
Note
♦ For removing the camshaft adjuster of the exhaust camshaft,

you only need to detach the engine support and the lower
toothed belt guard.
wage
♦ The bolts must be unscrewed far enough to enable this.
es n
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♦ Then, the top part of engine support is swung haway
oris from the tee
engine. aut or
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pt
– Detach engine support ⇒ page 48 .

du
an
itte
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ility
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– Unscrew bolts -arrows- and remove cover from camshaft ad‐

h re
juster for exhaust camshaft.

hole
spec
es, in part or in w
– The camshaft must be turned to gain access to all bolts.

t to the co
– Remove cover from camshaft adjuster of exhaust camshaft.

rrectness of i
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Prote AG.

Jetta 2015 ➤

• The counter-hold tool - T10554- can be inserted in only one
position.
NOTICE
– Guide in counter-hold tool - T10554- between camshaft ad‐

juster and engine support.
– Turn counter-hold tool - T10554- so that counter-hold tool -
T10554- can be inserted in holes -arrows- as shown in illus‐
tration.
AG. Volkswagen A
– Fit counter-hold tool - T10554- so thatolitksrests
wage flat against cam‐does n
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shaft adjuster -1-. db
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– Loosen bolt -1- one turn. Secure exhaust camshaft adjuster
wit
, is n
against turning with counter-hold tool - T10554- and counter-
h re
hold tool - T10172- .
hole
spec
– Loosen securing bolt of inlet camshaft adjuster ⇒ page 141 .
es, in part or in w
t to the co
– Remove camshaft adjuster of exhaust camshaft.
Installing
rrectness of i
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– Install camshaft adjuster. yri
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Prote AG.
– Renew bolts -1- and -2- for camshaft adjusters, and screw
them in loosely.
NOTICE
3. Valve gear 151

Jetta 2015 ➤
Pre-tightening
stages.
holding.
adjuster, inlet camshaft
1 -1- 15 Nm
2 -1- 50 Nm
– Hold exhaust camshaft in position using counterhold tool -

T10554- and counterhold tool - T10172- .
stages.
adjuster, exhaust camshaft
1 -1- 15 Nm
2 -1- 50 Nm
AG. Volkswagen AG d
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Tightening to final specified torque orise d
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– Tighten bolt -1- for camshaft adjuster to final specified
ss a torque. c
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-1- 135°
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– Tighten securing bolt for exhaust camshaft adjuster -1- to final
l purpos
specified torque.
nform
ercia
juster
m
-1- 135°
com
tion in
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Prote AG.

Jetta 2015 ➤

-1- 20 Nm
Assembling
Note
Make sure to remove the camshaft clamp and the crankshaft

locking pin before cranking the engine.
Torque settings lkswage es n
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♦ ⇒ “2.1 Assembly o
ir se overview - toothed belt cover”, page 94
ran
tee
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♦ ⇒ “2.2 Assembly
ss
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ce
le

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que”“ , page 98
rrectness of i
3.5 Removing and installing camshaft con‐

l purpos
trol valve 1 - N205-

Removing
nform
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– Unscrew bolt -2- and remove camshaft control valve 1 -

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N205- .
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Torque settings
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3. Valve gear 153

Jetta 2015 ➤
3.6 Removing and installing exhaust cam‐

shaft control valve 1 - N318-
Installed in vehicles with adjustable exhaust camshaft only.
Removing
– Unscrew bolt -1- and remove exhaust camshaft control valve
1 - N318- .
Installing
wage es n
Install in the reverse order of removal, observing the
yV
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• Renew O-ring. horis tee
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Torque settings ss
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3.7 Removing and installing valve stem
h re
ole,
seals
spec
t to the co
⇒ “3.7.1 Removing and installing valve stem seals (cylinder head
installed)”, page 154
⇒ “3.7.2 Removing and installing valve stem seals (cylinder head
rrectne
removed)”, page 158
s
3.7.1 Removing and installing valve stem
s o
cial p
f
seals (cylinder head installed)
inform
mer
atio
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n
c
♦ Spark plug socket - 3122B-
i
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♦ Valve stem seal fitting tool - 3365-

Jetta 2015 ➤
agen
4-cylinder
AG. Volkswaginjection
en AG
doesengine (1.4 l, 4V, EA211, turbocharger) - Edition 07.2019
olksw not
y V gu
♦ Removal rised band installation device for valve cotters ara
nte - VAS 5161
A- uwith
tho set -VAS 5161 A/32- eo
ra
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♦ Adapter - T40012-
l purpos
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com
tion in
r
te o
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Prote AG.
♦ Valve stem pliers - VAS 6770-
Procedure
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber bulkhead .
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulk‐
head .
– Unscrew bolts -arrows-. Remove heat shield for right drive
shaft.
-3-.
3. Valve gear 155

Jetta 2015 ➤
return line -2-.
– Remove camshaft housing ⇒ page 87 .
– Unscrew spark plugs with spark plug socket - 3122B- .

– Set piston of respective cylinder to “bottom dead centre”.
– Fit guide plate -VAS 5161A/32-1- onto cylinder head and se‐ lkswage es n
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cure with knurled screws -VAS 5161/12- . d byV
o
ua
ran
ir se tee
– Screw adapter - T40012- into the respective spark plug thread
utho
or
hand-tight. ss
a ac
ce
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nl
– Connect adapter to compressed air supply using a commer‐
pt
du
an
cially available union and apply pressure continuously.
itte
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• Minimum pressure: 6 bar.
ility
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– Insert punch -VAS 5161/3A- into guide plate.
h re
hole
spec
– Use a plastic hammer to knock loose the firmly seated valve
es, in part or in w
cotters.
t to the co
– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.
rrectness of i
– Slide sleeve -VAS 5161 A/32-1- onto assembly cartridge and
l purpos
insert cartridge into guide plate -VAS 5161 A/32-2- .

nform
– Attach pressure fork -VAS 5161/2- to toothed piece and press

ercia
assembly cartridge down.

m
at
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– At the same time, turn knurled screw of assembly cartridge

n
c
in t
clockwise until tips engage in valve cotters.

or
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ate
do
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– Move knurled screw back and forth to press apart valve cotters
p
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and capture them in assembly cartridge.

for
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– Release pressure fork.
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– Remove installation cartridge. yri
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– Unbolt guide plate and move to side.
agen
Prote AG.
• The compressed air hose remains connected.

– Remove valve spring and valve spring plate.

Jetta 2015 ➤
– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
Risk of damage when installing valve stem seals.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
– Lightly oil sealing olip
ris of valve stem seal -A-.
e nte
eo
th
u
avalve stem oil seal -A- onto valve guide using r ac
– Carefully pressss
valve stem seal fitting tool - 3365- .
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
If the valve cotters have been removed from the assembly car‐
l purpos
tridge, they must first be inserted into the insertion device -

VAS 5161 A/32-3- .
nform
ercia
• Larger diameter of valve cotters faces upwards.

m
at
– Press assembly cartridge onto insertion device from above

om
io
and pick up valve cotters.

n
c
in t
or
his
e
– Insert valve spring and valve spring plate. For installation po‐
at
do
riv
sition of valve spring refer to ⇒ page 135 .

p
cum
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en
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cted agen
Prote AG.
3. Valve gear 157

Jetta 2015 ➤
– Bolt guide plate -VAS 5161 A/32- onto cylinder head again.
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -
VAS 5161 A/32-2- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Assembling
– Install oil supply line -1- and oil return line -2-, and tighten bolts
-arrows-.
– Connect connector -4- to oil pressure switch - F1- -3-.

– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
and installing plenum chamber bulkhead .
. Volkswagen AG
gen AG does
– Install plenum chamber cover ⇒ General body repairs, Vol
kexte‐
swa not
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly
ed
by gu
ara
overview - plenum chamber cover . ho
ris nte
eo
t
au ra
– Install spark plugs ⇒ Maintenance ; Bookletss 821 . c
ce
le
un
pt
– Install camshaft housing ⇒ page 87 .
an
d
itte
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pe
ility
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Torque settings
h re
hole
spec
es, in part or in w
t to the co
Bolts -1- 25 Nm
Bolts for oil supply line 9 Nm
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
thi
3.7.2 Removing and installing valve stem

s
iva
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seals (cylinder head removed)

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♦ Valve stem seal fitting tool - 3365-
ht
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by
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Prote AG.

Jetta 2015 ➤
♦ Removal and installation device for valve cotters - VAS 5161

A- with set -VAS 5161 A/32-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
lkswage es n
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ir se tee
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ss
ce
e
nl
pt
du
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itte
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ility
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♦ Valve stem pliers - VAS 6770-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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en
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Prote AG.
3. Valve gear 159

Jetta 2015 ➤
Procedure
– Remove cylinder head ⇒ page 83 .
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seals are to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.
– Fit guide plate -VAS 5161A/32-1- onto cylinder head and se‐
cure with knurled screws -VAS 5161/12- .
– Insert punch -VAS 5161/3A- into guide plate.
– Use a plastic hammer to knock loose the firmly seated valve
cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161 A/32-1- onto assembly cartridge
wage
and
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does
insert cartridge into guide plate -VAS 5161 A/32-2-
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– Attach pressure fork -VAS 5161/2- to toothed
ris piece and press nte
tho e
assembly cartridge down. sa
u or
ac
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– At the same time, turn knurled screw of assembly cartridge
ce
le
un
pt
clockwise until tips engage in valve cotters.

an
d
itte
y li
rm
ab
– Move knurled screw back and forth to press apart valve cotters
pe
ility
and capture them in assembly cartridge.

ot
wit
, is n
h re
– Release pressure fork.

hole
spec
– Remove installation cartridge.

es, in part or in w
t to the co
– Unbolt guide plate and move to side.

– Remove valve spring and valve spring plate.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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iva
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
– Pull off valve stem seal using valve stem pliers - VAS 6770- .
Note
Risk of damage when installing valve stem seals.
AG. Volkswagen AG d
– Lightly oil sealing lip of lvalve
ksw stem seal -A-.
agen oes
no
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by
– Carefully press valve
ris
ed stem oil seal -A- onto valve guide using
ara
nte
valve stem seal
ut
ho fitting tool - 3365- . eo
r a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
If the valve cotters have been removed from the assembly car‐
rrectness of i
tridge, they must first be inserted into the insertion device -

VAS 5161 A/32-3- .
l purpos
• Larger diameter of valve cotters faces upwards.

nform
ercia
– Press assembly cartridge onto insertion device from above

and pick up valve cotters.
m
at
om
io
– Insert valve spring and valve spring plate. For installation po‐
n
c
in t
r
sition of valve spring refer to ⇒ page 135 .

o
his
ate
do
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en
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– Bolt guide plate -VAS 5161 A/32- onto cylinder head again.
ht
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by
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -
cted agen
Prote AG.
VAS 5161 A/32-2- into guide plate.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
– Install cylinder head ⇒ page 83 .
3. Valve gear 161

Jetta 2015 ➤

pulley
AG. Volkswagen AG d
agen oes
olksw not
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ara
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♦ Knurled screws - T10554/2- (not illustrated)
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t to the co
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cial p
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mer
atio
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Removing
c
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Note
um
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♦ Place a cloth under the camshaft adjuster and tensioning roller C py
ht. rig
to catch the engine oil which runs out. rig ht
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♦ The contact points between the toothed belt and components cted agen
Prote AG.
- such as camshaft pulleys, tensioning roller and idler pulley -
must be kept free of oil.

– Loosen bolt for inlet camshaft adjuster ⇒ page 145 .

Jetta 2015 ➤

T10172- and adapter - T10172/1- .
– Loosen bolt -1-.
– Unscrew securing bolt -1- of toothed belt pulley, and remove
toothed belt pulley.
Installing
Note
Before installing the camshaft adjuster, ensure that the guide

sleeve is inserted in the camshaft.

olks
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– Renew bolt -1- for camshaftoris adjuster of inlet camshaft, and tee
th or
screw it in loosely.ss au ac
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– Renew bolt -2- for exhaust camshaft pulley, and screw it in

un
pt
an
loosely.
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Installing
es, in part or in w
t to the co

rrectness of i
Note
l purpos
Make sure to remove the camshaft clamp and the crankshaft

locking pin before cranking the engine.
nform
mercia
a
com
Torque settings
tion in
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• ⇒ “2.1 Assembly overview - toothed belt cover”, page 94

thi
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• ⇒ “2.2 Assembly overview - toothed belt”, page 95

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• ⇒ “3.1 Assembly overview - crankcase breather system”, page

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183 Cop py
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• ⇒ “2.1 Assembly overview - charge air system”, page 251 p by
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3. Valve gear 163

Jetta 2015 ➤
4 Inlet and exhaust valves

⇒ “4.1 Checking valve guides”, page 164
⇒ “4.2 Checking valves”, page 164
⇒ “4.3 Valve dimensions”, page 165
4.1 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
AG. Volkswagen AG d
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♦ Dial gauge - VAS 6079- d by gu
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es, in part or in w
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Test sequence
l purpos
– Insert valve in guide. Valve stem end must be flush with guide.
On account of differing stem diameters, only use inlet valve in
nform
inlet valve guide and exhaust valve in exhaust valve guide.

mercia
– Determine rock.
at
om
ion
c
• Wear limit: 0.5 mm.

in t
or
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ate
– If the wear limit is exceeded, repeat the measurement with

do
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new valves.
um
for
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– Renew cylinder head if wear limit is still exceeded.
yi Co
Cop py
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Note
by lksw
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Prote AG.
Valve guides cannot be exchanged.
4.2 Checking valves

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

Jetta 2015 ➤
4.3 Valve dimensions
Note
Never rework the inlet and exhaust valves. Only lapping-in is per‐
mitted.
AG. Volkswagen AG d
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Dimension Inletedvalve
by
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Outlet valve gu
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∅a mm aut 28.5
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4. Inlet and exhaust valves 165

Jetta 2015 ➤
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 166
⇒ “1.2 Engine oil:”, page 169
⇒ “1.3 Removing and installing lower part of sump”, page 170
⇒ “1.4 Removing and installing upper part of sump”, page 174
⇒ “1.5 Removing and installing oil pump”, page 178
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 179
1.1 Assembly overview - sump/oil pump
Note
♦ Metal shavings or a large quantity of small metal particles

G. Volkswage
found during engine repair could indicate that the wacrankshaft
gen A n AG d
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bearings or conrod bearings are damaged.bTo olks
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not
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sequent damage, the following work must ris be carried out fol‐
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tho
and renew oil eo
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spray jets, engine oil cooler and oilss filter. c
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♦ Oil spray jet and pressure relief valve ⇒ page 76 .
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Prote AG.
166 Rep. gr.17 - Lubrication

Jetta 2015 ➤
1 - Nut
❑ 9 Nm
2 - Oil level and oil temperature
sender - G266-
⇒ page 179
3 - Seal
4 - Oil drain plug
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❑ To be renewed on 1st oil utho r eo
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❑ Oil drain plug with non-
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5 - Seal
spec
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❑ For oil drain plug instal‐
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led on 1st oil change
rrectness of i
6 - Lower part of sump
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⇒ page 170
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7 - Bolt
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❑ 5 Nm +90°
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8 - Dowel sleeve
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10 - Drive chain
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❑ For oil pump.
❑ Before removing, mark running direction with paint
11 - Bolt
12 - Upper part of sump
13 - Baffle plate
14 - Sprocket
❑ For oil pump drive.
15 - Dowel pin
16 - Oil filter
❑ Observe notes ⇒ page 166
❑ Before installing, coat seal with clean engine oil.
❑ Removing and installing ⇒ Maintenance ; Booklet 821
❑ If the connecting union for oil filter in sump became loose ⇒ page 168
1. Sump, oil pump 167

Jetta 2015 ➤
❑ 20 Nm
17 - Seal
18 - Oil pump
19 - Bolt
❑ 10 Nm
20 - O-ring
21 - Oil intake tube
❑ Clean strainer if soiled
22 - Bolt
❑ Tightening sequence ⇒ page 168
Tightening connecting union for oil filter agen

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Use only the two nuts -3 and 4- for this procedure. ss c
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• Hexagon nut , qty. 2, ⇒ Electronic Parts Catalogue (ETKA)
du
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– Screw nuts -3- and -4- onto connecting union -2-, and coun‐
erm
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terlock them.
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– Tighten connecting union -2- using nut -3-.
h re
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– Loosen the two nuts and remove them, taking care not to
es, in part or in w
loosen the connecting union.
t to the co
Torque settings
rrectness of i
l purpos
Connecting union -2- 50 Nm
nform
ercia
Lower part of sump - specified torque and tightening sequence

m
– Tighten bolts in stages in the sequence shown. at

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2 Bolts -1 to 19- 12 Nm
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Jetta 2015 ➤
Upper part of sump - specified torque and tightening sequence

AG. Vo lksw
1 Bolts -1 to 19- Screw in swby
agenhand as far asAstop
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2 Bolts -arrows- Screw e d by V
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3 Bolts -1 to 19-uth 8 Nm
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5 Bolts -arrows- Specified torque ⇒ Rep. gr. 34 ; Re‐
an
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moving and installing gearbox; Speci‐
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Markings on oil dipstick
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1 - Max. mark
l purpos
2 - Min. mark
nform
a - Area above hatched field up to max. mark: Do not top up with
ercia
engine oil!
m
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b - Oil level within hatched zone: engine oil can be added
n in
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c - Area from min. mark up to hatched field: top up, max. 0.5 l of thi
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Engine oil capacity
AG.
With oil filter, 4.0 l

Engine oil specifications
⇒ Maintenance ; Booklet
Changing engine oil: ⇒ Maintenance ; Booklet “Engine oil: drain”.
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter! Markings ⇒ page 169 .

Jetta 2015 ➤
1.3 Removing and installing lower part of

sump
Special tools and work‐
shop equipment re‐
quired
♦ Wedges - T10383/2-
♦ Applicator gun - VAS

6966-
AG. Volkswagen AG d
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♦ Sealant remover
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ole,
brush
spec
♦ Safety goggles
t to the co
♦ Sealant ⇒ Electronic
parts catalogue (ET‐
rrectne
KA)
Cutting tool - T10561-
ss o
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1- Bolt
inform
mer
2- Washer
atio
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3- Bracket
n
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4- Knife
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5- Guide
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6- Handle
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7- Inserts for support yri
p by
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(rod) for conver‐
c by lksw
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sion of handle
Prote AG.
8- Bolt

Jetta 2015 ➤
9- Support
Removing
• Remove noise insula‐
tion ⇒ General body
repairs, exterior; Rep.
gr. 66 ; Noise insula‐
tion; Assembly over‐
view - noise insula‐
tion .
• Drain engine oil
⇒ Maintenance ;
Booklet 821 .
– Disconnect electrical connector -1- on oil level and oil temper‐

ature sender - G266- .
– Remove oil level and oil temperature sender - G266-
⇒ page 179 .
– Loosen and unscrew bolts in the sequence -19 to 1-.
AG. Volkswagen AG d
agen oes
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– Separate bonded joint between bottom section of sump -4-

and top section of sump -1-.
rrectness of i
– Use cutting tool - T10561- to do this.

l purpos
Note
nf
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m
atio
♦ The sump is sealed with liquid sealant -2- ⇒ Electronic Parts

om
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Catalogue .
or c
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♦ When hardened, the sealant has a high adhesive strength.

t
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– Position cutting tool - T10561- on seal -arrows- without it cant‐

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171
AG.
1. Sump, oil pump
AG. Volkswagen AG d
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Jetta 2015 ➤ rised
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4-cylinder injectionaengine
ut
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(1.4 l, 4V, EA211, turbocharger) - Editionor a07.2019
ss c
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nl
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– Do not cant cutting tool - T10561- when doing this.
ility
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h re
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– Do not lever with cutting tool - T10561- .
spec
es, in part or in w
t to the co
– Perform procedure at other points as described until sump is
detached.
– Use wedge - T10383/2- to detach further.
rrectness of i
– Insert wedge - T10383/2- at detached points where possible.
l purpos
– Using a plastic hammer carefully drive in wedge.
nf
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– Carefully detach sump (bottom section) from adhesive bond.
orm
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atio
– Fit wedge - T10383/2- at another position and detach the bon‐
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– Apply screwdriver at position marked with -arrow-, and care‐
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fully lever off lower part of sump.
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– Carefully detach lower part of sump from adhesive bond using Cop py
a commercially available scraper. ht. rig
rig ht
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Installing
by c lksw
cted agen
Prote AG.
– Cover open parts of engine.
– Spray sealing surface with sealant remover and leave to act.
– Remove sealant residues from sump upper part with a flat
scraper.
CAUTION
Risk of eye injury caused by sealant residue.
– Remove sealant residue from sump (bottom section) using a

rotating plastic brush, for example.

Jetta 2015 ➤
– Observe use-by-date of sealant.

2 mm).
Danger of blocking lubrication system with excess sealant.
Do not apply sealant bead thicker than specified.

– Apply bead of sealant -arrow- from cartridge gun - VAS 6966-
onto clean sealing surface of bottom section of sump as shown
in illustration.
• Thickness of sealant bead: 2 to 3 mm.
– Take particular care when applying sealant bead in area of the
sealing flange.
olkswagen AG
en AG. V
– The lower sump section must be olkinstalled
swa
g
within 5 minutes
does
of
not
the sealant being applied. ed by V gu
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or
– Position bottom section
au
thof sump and tighten bolts eo
ra
⇒ page 168 . ss c
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nl
pt
– Install oil level and oil temperature sender - G266-
du
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⇒ page 179 .
y li
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ility
• Allow sealant to cure for approx. 30 minutes after installing
ot p
lower part of sump. Only then fill with engine oil.

wit
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– Replenish engine oil, and check oil level ⇒ Maintenance ; spec

Booklet 821 .
es, in part or in w
t to the co
Torque settings
♦ ⇒ Fig. ““Lower part of sump - specified torque and tightening
rrectness of i

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or
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ate
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Cop py
t. rig
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co lksw
by
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Prote AG.

Jetta 2015 ➤
1.4 Removing and installing upper part of

sump
AG. Volkswagen AG d
agen
Special tools and work‐ Volksw
oes
not
gu
shop equipment re‐ d by ara
quired rise nte
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♦ Hexagon key - ss c
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T10058-
nl
pt
du
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itte
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erm
ab
ility
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l purpos
♦ Wedges - T10383/2-
nform
mercia
at
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ion
c
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or
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ate
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
♦ Applicator gun - VAS

6966-
♦ Scraper
♦ Commercially availa‐
ble scraper
♦ Sealant remover
♦ Hand drill with plastic
brush
♦ Safety goggles
♦ Sealant ⇒ Electronic
parts catalogue (ET‐
KA)
Cutting tool - T10561-

Jetta 2015 ➤
1- Bolt
2- Washer
3- Bracket
4- Knife
5- Guide
6- Handle
7- Inserts for support
(rod) for conver‐
sion of handle
8- Bolt
9- Support
Removing
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐
moving and installing air conditioner compressor from and to
bracket . wage
es ks not
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– Remove sump (bottom section) ⇒ page 170 . ed by ara
nte
ris
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– Remove oil pump ⇒ page 178 . au
t ra
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un
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an
d
itte
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rm
ab
pe
ility
ot
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– Unscrew securing bolts -arrows- for gearbox to upper section
h re
hole
of sump -1-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
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t.
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Cop py
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by c lksw
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Prote AG.

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
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– Detach bonded joint between top section of sump -4- and en‐
erm
ab
gine -1-.
ility
ot p
wit
is n
– Use cutting tool - T10561- to do this.
h re
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spec
Note
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♦ The sump is sealed with liquid sealant -2- ⇒ Electronic Parts
Catalogue .
♦ When hardened, the sealant has a high adhesive strength. rrectness o
cial p
– Separation is made centrally between bolts -3-.

inform
mer
– Position cutting tool - T10561- on seal -arrows- without it cant‐

atio
m
ing.
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te
– Drive in cutting tool - T10561- -3- using a rubber hammer as

sd
iva
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r
far as it will go -arrow-.

p
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– Do not cant cutting tool - T10561- when doing this.

t.
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.
– Do not cutting tool - T10561- sideways.
ht rig
rig ht
py by
co Vo
– Do not lever with cutting tool - T10561- .
by lksw
cted agen
Prote AG.
– Perform procedure at other points as described until sump is
detached.
– Use wedge - T10383/2- to detach further.
– Insert wedge - T10383/2- at detached points where possible.
– Using a plastic hammer carefully drive in wedge.
– Carefully detach sump (bottom section) from adhesive bond.
– Fit wedge - T10383/2- at another position and detach the bon‐
ded joint in the same way.

Jetta 2015 ➤
– Carefully lever off sump from cylinder block at recess -arrow-

using assembly lever.
– Carefully detach upper part of sump from adhesive bond.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove baffle plate.
Danger of soiling lubrication system.
– Cover open parts of engine.
Installing
– Renew gaskets, oil seals and self-locking nuts.
AG. Volkswagen n AG do
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– Remove sealant residues
Vol from cylinder block with aotflat
n
gu scra‐
by
per. ris
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CAUTION
ss
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e
nl
pt
Risk of eye injury caused by sealant residue.
du
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itte
y li
erm
ab
ility
ot p
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– Remove sealant residue from upper part of sump, e.g. with
hole
rotating plastic brush.
spec
es, in part or in w
t to the co
– Check oil galleries in upper part of sump and cylinder block for
soiling.
– Remove any oil and grease from sealing surfaces. rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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te
– Observe use-by date of sealant.

a
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or

f
en
ng
t.
2 mm). Cop
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t. rig
Danger of blocking lubrication system with excess sealant. opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤

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does gen AG
– Apply bead of sealant Vol
k-arrow-
swa from cartridge gun n- oVAS
t gu
6966-
onto clean sealing ed bsurface of bottom section of sump as
y arshown
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au ac
• Thickness
ss of sealant bead: 2 to 3 mm.
ce
e
nl
pt
du
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Note
erm
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The top section of the sump must be installed within 5 minutes of
wit
, is n
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the sealant being applied.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Check that dowel pin -2- is securely seated in cylinder block.

m
at
om
– Attach baffle plate -1- to cylinder block.
ion
c
in t
or
– Position top section of sump and tighten bolts ⇒ page 169 . his
ate
do
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or

f
en
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op
– Install oil pump ⇒ page 178 . C py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote AG.

stalling air conditioner compressor from and to bracket .
– Replenish engine oil, and check oil level ⇒ Maintenance ;
Booklet .
Torque settings
♦ Securing gearbox to engine ⇒ Rep. gr. 34 ; Removing and
installing gearbox; Installing gearbox
1.5 Removing and installing oil pump

Removing
– Remove sump (bottom section) ⇒ page 170 .
– Unclip cover for oil pump chain sprocket -arrows-.

Jetta 2015 ➤

– Guide out oil pump with chain sprocket under drive chain.
Installing
– Check that dowel sleeves -1, 3- are fitted in oil pump.
– Fit seal with strainer -2- in oil pump.
– Turn oil pump chain sprocket by hand to check oil pump for
n AG. Volkswagen AG
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Renew sluggish oil pump.
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– Fit oil pump with chain sprocket into drive chain and secure.
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– Replenish engine oil, and check oil level ⇒ Maintenance ;
Booklet . t to the co
Torque settings
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1.6 Removing and installing oil level and oil

ss o
temperature sender - G266-

cial p
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mer
Removing
atio
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• Engine oil drained ⇒ Maintenance ; Booklet 821 .

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Prote AG.

Jetta 2015 ➤

– Undo nuts -1- and remove oil level and oil temperature sender
- G266- -item 3-.
Installing
– Renew oil seal -4-.
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 821 .
Torque settings
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Prote AG.

Jetta 2015 ➤
2 Engine oil cooler

⇒ “2.1 Assembly overview - engine oil cooler”, page 181
⇒ “2.2 Removing and installing engine oil cooler”, page 181
2.1 Assembly overview - engine oil cooler
1 - Engine oil cooler gen AG. Volkswagen AG

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⇒ page rise 181
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❑ 8 Nm +90°
wit
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3 - Oil seals
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Prote AG.
2.2 Removing and installing engine oil cool‐

er
Removing
2. Engine oil cooler 181

Jetta 2015 ➤
– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
– Insert new O-rings.
– Install intake manifold ⇒ page 274 .
Torque settings
♦ ⇒ “2.1 Assembly overview - engine oil cooler”, page 181
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Prote AG.

Jetta 2015 ➤
3 Crankcase ventilation
⇒ “3.1 Assembly overview - crankcase breather system”,
page 183
⇒ “3.2 Removing and installing oil separator”, page 184
3.1 Assembly overview - crankcase breather system
1 - Hose
❑ For crankcase ventila‐
tion. wage es n
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2 - Cover ris
ed nte
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❑ Fors aoil
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3 - Oil separator
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⇒ page 184
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❑ Renew if damaged
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4 - O-ring
hole
spec
es, in part or in w
t to the co
❑ Moisten with oil before
installing
5 - Union
rrectness of i
❑ Check for correct posi‐
l purpos
tioning
6 - Hose
nform
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at
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7 - Bolt
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❑ Self-locking
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⇒ page 183 yri
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Oil separator - specified torque and sequence

– Tighten bolts in the sequence -1 … 9-.
Tighten bolts in the sequence 9 Nm
-1 … 9-.
3. Crankcase ventilation 183

Jetta 2015 ➤
3.2 Removing and installing oil separator

♦ Applicator gun - VAS 6966-
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♦ Scraper ss
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♦ Commercially available studs, M 6 x 20 mm, qty. 2
pt
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♦ Sealant remover
erm
ab
ility
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♦ Sealant ⇒ Electronic parts catalogue (ETKA)
wit
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Removing
hole
spec
es, in part or in w
t to the co
sulation .
– Unscrew bolts -arrow- and push charge air cooling pump -
rrectness of i
V188- to one side.
l purpos
nform
mercia
at
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ion
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– Pull off crankcase breather hose -3-. cop Vo
by lksw
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Prote AG.
– Release fasteners -2- -arrow- on cover -1- for oil separator and
detach cover.

Jetta 2015 ➤

– Carefully release oil separator from bonded joint.
Installing
Note
♦ Danger of soiling lubrication system.

♦ Cover open parts of engine.
– Remove sealant residues from cylinder block with a flat scra‐

per.
– Screw 2 M 6 x 20 mm studs a few turns into holes -arrows-.
AG. Volkswagen AG d
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• Observe use-by date of sealant.

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hole
spec
2.0 mm).
es, in part or in w
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Danger of blocking lubrication system with excess sealant.

rrectness of i
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mercia
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tion in

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– Apply bead of sealant -arrow- with cartridge gun - VAS 6966-

iva
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onto clean sealing surface of oil separator as shown in illus‐

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• Width of sealant bead: 2.0 mm.
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Note
Prote AG.
The top section of the sump must be installed within 5 minutes of

the sealant being applied.
3. Crankcase ventilation 185

Jetta 2015 ➤
– Fit oil separator onto studs -arrows- and push onto crankcase.
– Start securing bolts.
– Unscrew studs.
– Oil separator – specified torque and tightening sequence
⇒ page 183 .
tion .
Torque settings
♦ ⇒ Fig. ““Oil separator - specified torque and sequence”“ , page
183
♦ ⇒ “2.2 Assembly overview - electric coolant pump”,
page 208
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Prote AG.
Rep. gr.17 - Lubrication
Jetta 2015 ➤
4 Oil filter, oil pressure switch

⇒ “4.1 Assembly overview - oil filter/oil pressure switch”,
page 187
⇒ “4.2 Removing and installing oil pressure switch F1 ”,
page 188
⇒ “4.3 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 189
⇒ “4.4 Checking oil pressure”, page 189
⇒ “4.5 Removing and installing oil pressure regulating valve N428
”, page 191
4.1 Assembly overview - oil filter/oil pressure switch
1 - Oil filter
❑ Observe notes
⇒ page 166
❑ 20 Nm
2 - Oil pressure switch for re‐ AG. Volkswagen AG d
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❑ Screw in by hand 3 full ed by ara
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❑ Switch pressure 0.3 to ss a c
0.6 bar
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❑ Checking ⇒ page 189
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⇒ page 189
wit
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❑ 20 Nm
h re
ole,
spec
3 - Seal
t to the co
❑ Pinch off old seal and re‐
new ⇒ Electronic parts
rrectne
catalogue (ETKA)
4 - O-ring
ss o
cial p
f inform
5 - Valve for oil pressure con‐

mer
trol - N428-
atio
om

c
i
or
⇒ page 191
thi
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6 - Bolt
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❑ 8 Nm yi
t.
Co
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❑ Pinch off old seal and re‐ Prote AG.
new ⇒ Electronic parts
catalogue (ETKA)
8 - Oil pressure switch - F1-
❑ Screw in by hand 3 full turns
❑ Switch pressure 2.15 to 2.95 bar
4. Oil filter, oil pressure switch 187

Jetta 2015 ➤
❑ 20 Nm
4.2 Removing and installing oil pressure

switch - F1-
♦ Jointed wrench 24 mm - T40175-
AG. Volkswagen AG d
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Removing
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ility
• Fit all heat shield sleeves in the same place when installing.
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shaft.
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c
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– Remove oil pressure switch - F1- . Prote AG.
Installing
• If reusing oil pressure switch - F1- , seal must be renewed.
– Pinch off old seal and renew ⇒ Electronic parts catalogue
(ETKA)
– Check oil level ⇒ Maintenance ; Booklet .
Torque settings
♦ ⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page
187

Jetta 2015 ➤

switch for reduced oil pressure - F378-
♦ Jointed wrench 24 mm - T40175-
AG. Volkswagen AG d
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Removing s
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an
d
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take manifold and push it downwards slightly.
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– Place a cloth underneath to catch any escaping engine oil.
hole
spec
– Unscrew oil pressure switch for reduced oil pressure - F378-
es, in part or in w
t to the co
-1-.
Installing
rrectness of i
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• If reusing oil pressure switch for reduced oil pressure - F378- ,

seal must be renewed.
nform
ercia
– Pinch off old seal and renew ⇒ Electronic parts catalogue

(ETKA)
m
a
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tion in
– Check oil level ⇒ Maintenance ; Booklet .
r
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Torque settings
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♦ ⇒ “4.1 Assembly overview - oil filter/oil pressure switch”, page cum

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187
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4.4 Checking oil pressure
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Prote AG.
♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK. Checking ⇒ Maintenance ; Booklet .

Jetta 2015 ➤
• Engine oil temperature at least 80°C (radiator fan must have

run once)
– Remove oil pressure switch for reduced oil pressure - F378-
⇒ page 189 .
– Screw oil pressure tester - V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch for reduced oilgepressure
n AG. Volks-wF378-
agen AGinto
does
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hole in oil pressure tester - V.A.GV1342-
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– Start the engine. oris tee
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Check oil pressure at idling
ss and at 2000 rpm
ac
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• Oil pressure at idling speed: at least 0.6 bar.
pt
du
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• Oil pressure at 2000 rpm: at least 1.5 bar.
erm
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ility
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– Switch off engine.
wit
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Check oil pressure at 3,800 rpm
hole
spec
– Remove electrical connection from oil pressure control valve
es, in part or in w
t to the co
- N428- ⇒ page 192 .
– Start the engine.
rrectness of i
– Increase engine revs to 3800 rpm, and read oil pressure on oil
pressure tester - V.A.G 1342- .
l purpos
• Oil pressure at 3800 rpm: at least 2.8 bar.
nform
ercia
If specification is not attained:

m
at
– Connect electrical connection to oil pressure control valve -
om
ion
N428- ⇒ page 192 .
c
in t
or
his
te
– Interrogate the engine control unit event memory and delete

a
do
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all event entries ⇒ Vehicle diagnostic tester.

p
cum
for
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– Check oil pressure control valve - N428- ⇒ Vehicle diagnostic

t.
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tester.
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Note
Prote AG.
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault is found:
– Renew oil pump ⇒ page 178 .
Check oil pressure switch for reduced oil pressure - F378-
(brown):

Jetta 2015 ➤
– Connect brown wire of tester to earth (-).

– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch for reduced oil pressure - F378-
(brown) using cables from auxiliary test set - V.A.G 1594C- .
• LED must not light up.
– If LED lights up, renew oil pressure switch for reduced oil
pressure - F378- .
If LED does not light up:
– Start engine: At 0.3 to 0.6 bar the LED must light up, otherwise
renew oil pressure switch.
Checking oil pressure switch - F1- (blue)
– Switch off engine.
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch - F1- (blue) using cables from auxiliary
test set - V.A.G 1594C- .
• LED must not light up.
– If LED lights up, renew oil pressure switch oil pressure switch
- F1- .
If LED does not light up: agen
AG. Volkswagen AG d
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– Remove electrical connection from d b oil pressure control valve
y gu
ara
- N428- ⇒ page 192 . rise nte
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– Start engine and increasesrpm: At pressure of 2.15 to 2.95 bar
s c
LED must light up, otherwise renew oil pressure switch.
ce
le
un
pt
an
d
itte
– Connect electrical connection to oil pressure control valve -
y li
erm
ab
N428- ⇒ page 192 .
ility
ot p
wit
– Install oil pressure switch for reduced oil pressure - F378-
is n
h re
⇒ page 189 .
ole,
spec
– Interrogate the engine control unit event memory and delete t to the co
all event entries ⇒ Vehicle diagnostic tester.
Torque settings
rrectne

187
ss o
cial p

inform
regulating valve - N428-

mer
atio
om
Removing
n
c
i
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• Fit all heat shield sleeves in the same place when installing.
t
sd
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cum

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fo
en
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t.
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op
sulation . C py
t. rig
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– Detach heat insulation sleeves.
p by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤

• Place a cloth underneath to catch any escaping engine oil.
– Unscrew bolt -2- and pull off valve for oil pressure control -
N428- .
Installing
• Renew O-ring.
AG . Volkswage
– Install noise insulation ⇒ General body repairs,
ksw
agen exterior; nRep.
AG do
es n
l
gr. 66 ; Noise insulation; Assembly by overview – noise insula‐
Vo ot g
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tion . rised ran
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Torque settings s au ra
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do
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t.
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Cop py
t. rig
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pyri by
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Prote AG.

Jetta 2015 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 193
⇒ “1.2 Assembly overview - engine preheater”, page 194
⇒ “1.3 Checking cooling system for leaks”, page 194
⇒ “1.4 Draining and adding coolant”, page 197
⇒ “1.5 Removing and installing engine preheating element Z97 ”,
page 203
1.1 Connection diagram - coolant hoses
Note
♦ The arrows point in the direction of coolant flow.

♦ The arrows on the coolant pipes and on the ends of hoses
must be aligned with each other.
1 - Coolant expansion tank

2 - Cap
❑ For coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 197 n AG. Volkswagen AG do
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3 - Cylinder head/cylinder ir se
d b ua
ran
block tho tee
or
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❑ After renewing, replen‐ ss
ish coolant ⇒ page 199
ce
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pt
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4 - Engine preheating element

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- Z97-
ility
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❑ Not fitted
wit
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5 - Turbocharger
ole,
spec
6 - Integrated exhaust manifold

t to the co
7 - Heat exchanger for heater

❑ After renewing, replen‐
rrectne

8 - Radiator outlet coolant -
ss
G62-
o
cial p
f in
9 - Coolant pump
form
mer
❑ With thermostat hous‐

atio
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ing
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10 - Engine oil cooler

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11 - Radiator outlet coolant

um
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temperature sender - G83-

en
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t.
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12 - Radiator for engine cool‐ t. C rig
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❑ After renewing, replen‐ cted agen
Prote AG.
1. Cooling system/coolant 193

Jetta 2015 ➤
13 - Charge air cooling pump - V188-

14 - Radiator for charge air cooling circuit
❑ After renewing, replenish coolant ⇒ page 199
15 - Charge air cooler in intake manifold
16 - Auxiliary heater
❑ Optional equipment
1.2 Assembly overview - engine preheater
1 - Nut
❑ 10 Nm
2 - Bracket
❑ Note installation posi‐
tion ⇒ page 203
3 - Protective pad
tion ⇒ page 203
4 - Clip
tion ⇒ page 203
5 - Hose clamp
6 - Coolant hose
❑ To engine
❑ Connection diagram for
coolant hoses
⇒ page 193
7 - O-ring agen
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❑ Connection diagram for ut
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coolant hoses ss a c
⇒ page 193
ce
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nl
pt
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9 - Bolt
itte
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❑ 9 Nm
ility
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10 - Engine preheating ele‐

, is n
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ment - Z97-
hole
spec

es, in part or in w
⇒ page 203
t to the co
11 - Clip
rrectness of i
12 - Connecting cable
❑ 220 V
l purpos
13 - Front trim
nf
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m
atio
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1.3 Checking cooling system for leaks

o
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Rep. gr.19 - Cooling cted agen
Prote AG.
Jetta 2015 ➤
♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
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Procedure
, is n
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es, in part or in w
Note
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To perform the leakage test correctly, first run a self-test on the

cooling system tester - V.A.G 1274 B- .
rrectness of i
l purpos
Self-test of cooling system tester - V.A.G 1274 B-

– Operate cooling system tester - V.A.G 1274 B- several times.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

Jetta 2015 ➤
– Build up a pressure of 3.0 bar on cooling system tester .

– Observe pressure on pressure gauge of cooling system tester
for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
not be used.
Checking cooling system for leaks
CAUTION
On a warm engine, the cooling system is under high pressure.
There is a risk of injury to the skin and parts of the body due to
scalding.
– Carefully open filler cap -1- on coolant expansion tank -2- in

• Engine at operating temperature.
AG. Volkswagen AG d
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– Fit cooling system tester - V.A.G 1274 B- with adapter - s
ce
e
V.A.G 1274/8- on coolant expansion tank.

nl
pt
du
an
itte
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– Using hand pump on tester, build up a pressure of approx.

erm
ab
1.0 bar.
ility
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– If this pressure is not maintained, locate and rectify leaks.

h re
hole
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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pyri by
Vo
o
by c lksw
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Prote AG.
196 Rep. gr.19 - Cooling

Jetta 2015 ➤
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto coolant filler cap.
– Build up pressure using hand pump of cooling system tester.
♦ The pressure relief valve must open at a pressure
wageof 1.6 to
es n
s
1.8 bar. yV
olk ot g
u b ara
ed nte
oris e
th or
au ac
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
1.4 Draining and adding coolant
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Refractometer - T10007 A-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Safety goggles
♦ Protective gloves

Jetta 2015 ➤
♦ Cooling system tester - V.A.G 1274 B-

Draining
CAUTION
scalding.

• Engine at operating temperature.
sulation .
– Disconnect connector -1- from radiator outlet coolant temper‐

ature sender - G83- -2-.
– Lift securing clip -3-, and remove lower right coolant hose from
radiator.
– Drain coolant.
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
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– Lift securing clip -arrow-, and disconnect lower right coolant

erm
ab
ility
hose from water radiator for charge air cooling circuit.

ot p
wit
is n
– Allow remaining coolant to drain out.

h re
ole,
spec
Filling
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
cum
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co
199
by lksw
cted agen
Prote 1. Cooling system/coolant
AG.
Jetta 2015 ➤
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, only ever use distilled water
when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . Other coolant additives may reduce cor‐
rosion protection substantially. The resulting damage could
lead to loss of coolant and subsequent major damage to the
engine.
♦ Mixed in the correct proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. Therefore, the cooling system
must be filled all year round with a coolant additive.
♦ Because of its high boiling point, the coolant improves the re‐
AG. Volkswagen
liability of the motor under heavy loads, particularly in coun‐
ksw
agen AG do
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tries with tropical climates. y Vol ot g
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db e ran
ris tee
♦ The refractometer - T10007A- or refractometer
ut
ho - T10007B- or
must be used to determine the current anti-freeze
ss
a value. ac
ce
e
♦ Scale -1- of the refractometer is calibrated for the coolant ad‐

nl
pt
du
an
ditives G12++ and G12evo.
itte
y li
erm
ab
♦ Scale -2- of the refractometer is calibrated for the coolant ad‐
ility
ot p
ditive G13.
wit
, is n
h re
♦ If it is not possible to ensure that the same type of coolant
hole
spec
additive is filled: always determine anti-freeze protection using
es, in part or in w
the scale for G13.
t to the co
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
rrectness of i
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
l purpos
ever, be increased only to a maximum of -48°C. Otherwise,

the cooling effect will be impaired. nf
ercia
♦ Do not reduce the coolant concentration by adding water even

rm
in warmer seasons and in warmer countries. Frost protection

m
atio
m
must be guaranteed down to at least -25°C.

o
n in
or c
thi
♦ The temperature reading on the refractometer corresponds to

te
sd
a
the »ice flocculation point«. Flakes of ice may start forming in

iv
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rp
cu
the coolant below this temperature.

o
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t.
yi
♦ Never reuse old coolant.
Co
Cop py
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gh
♦ Use only a water/coolant additive mixture as a slip agent for
ht
pyri by
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coolant hoses. by c lksw
cted agen
Prote AG.
Coolant mixture ratio

Frost Coolant additive Coolant ad‐ Distilled wa‐
protection to concentration ditive 1) ter 1)
-25°C 40% 3.2 l 4.8 l
-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending on the vehicle
equipment.
• Coolant: ⇒ Electronic parts catalogue (ETKA) .

Jetta 2015 ➤
Procedure
– Connect coolant hose with plug-in connector to radiator (bot‐
tom left) ⇒ page 228 .
lkswage es n
Vo ot g
– Connect coolant hose to bywater radiator for charge air cooling ua
ed ran
circuit (bottom right)or-arrow-.
is tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
– Fill coolant reservoir of -VAS 6096- with at least 10 litres of
pre-mixed coolant in correct mixture ratio:
s
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
s o
cial p
expansion tank.
f inform
mer
– Place cooling system charge unit - VAS 6096- on adapter -
atio
V.A.G 1274/8- .
om
n
c
i
or
n
– Feed vent hose -2- into a small container -3-.
thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
Exhaust air takes a slight quantity of coolant along with it; this
t. rig
gh ht
yri
should be collected.
p by
co Vo
by lksw
cted agen
Prote AG.
– Close valves -A- and -B- (turn lever transverse to direction of
flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 to 10 bar.

Jetta 2015 ➤ n AG. Volkswagen AG do
wage es n
yV
olks - Edition 07.2019 ot g
b ua
ed ran
ris tee
– Open valve -B-; turn lever in direction of flow to do this.
tho
or
au ac
ss
• The suction-jet pump reduces pressure in the cooling system
ce
le
un
to below atmospheric pressure.
pt
an
d
itte
y li
• The needle on the gauge should move into the green zone.
rm
ab
pe
ility
– Also, open valve -A- briefly.
ot
wit
, is n
h re
– To do this, turn lever in direction of flow so that hose of spare
hole
spec
container for cooling system charge unit - VAS 6096/1- is filled
es, in part or in w
with coolant.
t to the co
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
rrectness of i
• The suction-jet pump will continue generating a vacuum in the
l purpos
cooling system.
• The needle on the gauge must remain in the green zone.
nform
ercia
– Close valve -B-.

m
a
com
tion in
• The needle on the gauge should stop in the green zone. The
r
te o
thi
vacuum level in the cooling system is then sufficient for sub‐
s
iva
sequent filling.
do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
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pyri by
♦ If the needle does not reach the green zone, repeat the proc‐
co Vo
by lksw
cted agen
ess. Prote AG.
♦ If the vacuum drops, the cooling system must be checked for

leaks.
– Pull off compressed air hose.

– Open valve -A-.
• Vacuum in cooling system causes coolant to be extracted from
-VAS 6096- coolant reservoir and coolant system to be filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank.
– Fill coolant up to “max.” mark.

tion .
– On vehicles with auxiliary heater, switch on auxiliary heater for
about 30 seconds.
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor (press AC button to do
so).
• LED in the button must not light up.
– Tighten cap of coolant expansion tank until it engages.
– Start engine and run alternately at approx. 1500 rpm to max‐
imum of 2800 rpm until radiator fan starts operating.
– Switch off engine and let it cool off.

Jetta 2015 ➤
– Check coolant level.

– Screw adapter for cooling system tester - V.A.G 1274/8- again
onto expansion tank.
– Use cooling system tester - V.A.G 1274 B- to apply a pressure
of 1 bar to the cooling system.
– Use tester to relieve pressure and remove cooling system
tester - V.A.G 1274 B- .
– With engine running, fill coolant up to approx. 5 mm above
max. marking.
• When engine is cold, coolant level must be between “min” and
“max” marks.
• When engine is at operating temperature, it is permissible that
coolant level is at “max.” mark or above.
1.5 Removing and installing engine pre‐

heating element - Z97- n AG. Volkswagen A ge G do
swa es n
Special tools and workshop equipmentbyrequired
Vol
k ot g
ua
d ran
se
♦ Refractometer - T10007 A- thori tee
or
u a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

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

Jetta 2015 ➤
Removing AG. Volkswagen AG d

agen oes
olksw not
yV gu
CAUTION ised b ara
nte
or eo
th
On a warm engine, the cooling system sis
au under high pressure. ra
c
Hot steam/hot coolant can escape - risk
s of scalding.
ce
e
nl
pt
du
an
itte
scalding.
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
sulation .
l purpos

– Unclip locking mechanism -arrow-.
nf
ercia
or
– Pull off wiring -1- on engine preheating element - Z97- -2-.
m
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release hose clips -arrows-.

– Pull coolant hoses off engine preheating element - Z97- .
– Unscrew nuts -arrows- and remove engine preheating ele‐

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

Jetta 2015 ➤
Installation position of engine preheater heater element - Z97-

The locating element -arrow- must rest against bracket.
– Position protective pad and clamp as shown in illustration.
Torque settings
♦ ⇒ “1.2 Assembly overview - engine preheater”, page 194
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 206
⇒ “2.2 Assembly overview - electric coolant pump”, page 208
⇒ “2.3 Assembly overview - coolant temperature sender”,
page 210
⇒ “2.4 Removing and installing electric coolant pump”,
page 210
⇒ “2.5 Removing and installing coolant pump”, page 212
⇒ “2.6 Removing and installing thermostat”, page 216
⇒ “2.7 Removing and installing toothed belt pulley for coolant
pump”, page 219
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 220
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 221
2.1 Assembly overview - coolant pump, thermostat

n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
1 - Thermostat housing ed ran
oris tee
th or
❑ Removing and installing au ac
ss
⇒ page 216
ce
le
un
pt
❑ Observe tightening se‐
an
d
itte
quence when tightening
y li
rm
ab
to coolant pump
pe
ility
⇒ page 212 .
ot
wit
, is n
h re
2 - Thermostat
hole
spec
❑ For cylinder block cool‐
es, in part or in w
ant circuit
t to the co
❑ Starts to open at approx.
97 … 105°C
❑ Different versions. Re‐ rrectness of i
fer to ⇒ Electronic parts
l purpos
catalogue (ETKA)
nform
ercia
⇒ page 216
m
3 - Seal
com
tion in

r
te o
thi
s
iva
❑ Lightly coat with coolant

do
r
rp
before installing.
um
fo
en
ng
t.
4 - Coolant pump
yi Co
Cop py
t. rig
gh ht
yri
⇒ page 212
p by
co Vo
by lksw
cted
❑ Renew toothed belt as
agen
Prote AG.
well when renewing
coolant pump
5 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by
hand so that it screws
into old thread Then
tighten bolt to specified

Jetta 2015 ➤
4-cylinder injection engine (1.4
en AGl,
. 4V,
VolkswEA211,
agen AG turbocharger) - Edition 07.2019
ag does
ksw not
Vol gu
torque ed
by ara
nte
ris
❑ Specified torque and tightening t sequence ⇒ page
ho 208 eo
au ra
c
ss
6 - Seal
ce
e
nl
pt
du
an
itte
y li
❑ Ensure proper seating of seal
erm
ab
ility
ot p
❑ Lightly coat with coolant before installing.
wit
, is n
h re
7 - Toothed belt guard
hole
spec
❑ For toothed belt for coolant pump
es, in part or in w
t to the co
8 - Bolt
rrectness of i
❑ 20 Nm +90°
l purpos
9 - O-ring
❑ Not fitted
nform
ercia
10 - Toothed belt
m
at
om
ion
c
❑ Renew toothed belt as well when renewing coolant pump
in t
or
his
ate
11 - Crankshaft
do
priv
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
12 - Bolt
gh ht
pyri by
Vo
o
by c
❑ 8 Nm
lksw
cted agen
Prote AG.
13 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to torque.
14 - Cover
❑ For thermostat
15 - Seal
16 - Thermostat
❑ For main coolant circuit (radiator)
❑ Up to 11.2012: Starts to open at approx. 80°C
❑ As of 11.2012: Starts to open at approx. 87°C
❑ Fitting position ⇒ page 208
17 - Bolt
2. Coolant pump, regulation of cooling system 207

Jetta 2015 ➤
Installation position of thermostat for large cooling circuit

• Must be positioned with centring pin in guide -arrow- in ther‐
mostat housing.
Thermostat housing to coolant pump - specified torque and se‐

quence
– Tighten bolts in sequence -A … F-.
Bolts -A … F- 8 Nm
Cover for thermostat to thermostat housing - specified torque

– Tighten bolts for cover -1- in sequence -A to D-.
Bolts for cover -1- 7 Nm
-A … D- 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
2.2 Assembly overview - electric coolant pump

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
1 - Charge air cooling pump -

V188-
❑ with holder
⇒ page 210
2 - Coolant hose
3 - Bolt
❑ 8 Nm
4 - Coolant hose
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
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
2.3 Assembly overview - coolant temperature sender
1 - O-ring
2 - Radiator outlet coolant tem‐
perature sender - G83-
⇒ page 221
3 - Support ring
4 - O-ring
G62-
⇒ page 220
6 - Bolt
❑ 8 Nm
7 - Retaining clip
❑ Check for firm seating
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.4 Removing and installing electric coolant

pump
nform
ercia
⇒ “2.4.1 Removing and installing charge air cooling pump V188

m
at
”, page 210
om
ion
c
in t
or
2.4.1 Removing and installing charge air cool‐

his
ate
do
riv
ing pump - V188-

p
cum
for
en
ng

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

Jetta 2015 ➤
♦ Hose clamps to 25 mm - 3094-
lkswage es n
o ot g
byV ua
♦ Hose clip pliers - VAS ir se6362-
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos

nform
ercia
CAUTION
m
at
om
ion
c

in t
or

his
ate
do
riv
p
cum
or
scalding.
f
en
ng
t.
yi Co
– Wear protective gloves. t. Cop py
rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
AG.

sulation .

Jetta 2015 ➤

. Volkswagen AG
a gen AG d
– Place drip tray for workshop
Vol hoist - VAS 6208- underneath.
ksw
oes
not
g y ua
db r
– Clamp off coolant ohoses
ris
e
on charge air cooling pump - V188-antee
using hose clamps
auth -3094- . or
a
ss c
– Release hose clip -3- and remove coolant hose.
ce
e
nl
pt
du
an
– Unscrew bolt -2- and remove charge air cooling pump - V188- .
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
h re
hole
spec
• Secure all hose connections with the correct type of hose clips
es, in part or in w
(same as original equipment) ⇒ Electronic parts catalogue .
t to the co
rrectness of i
tion .
l purpos
– Check coolant level ⇒ page 203 .

Torque settings
nf
ercia
o
rm
m
page 208
atio
om
n in
or c
thi
2.5 Removing and installing coolant pump
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.

Jetta 2015 ➤
equipment required
AG. Volkswagen AG d
agen oes
ksw not
♦ Release tool - T10527- byV
ol
gu
ara
ed
is nte
♦ Release tool - T10527/1- thor eo
au ra
s c
Removing s
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
coal filter.
rrectness of i

l purpos
– Seal all openings in charge and intake air system using plugs
from engine bung set - VAS 6122- .
nform
ercia
– Renew bolts -arrows-.

m
at
– Thoroughly clean thread on turbocharger.

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

Jetta 2015 ➤
– Lay wiring harness to one side -arrows-.

– Unscrew bolts -1, 3- and remove cover -2- for toothed belt for
coolant pump.
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
– Move clear electrical wiring harness -1- and coolant hose -2-.
an
d
itte
y li
rm
– Release hose clips -arrows-, and disconnect all coolant hoses
ab
pe
ility
from coolant pump.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
– Detach coolant pump with toothed belt.
com
tion in
– Remove thermostat housing if coolant pump is being renewed
r
te o
thi
⇒ page 216 .
s
iva
do
r
rp
cum
Installing
fo
en
ng
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– Renew gasket for housing -arrows-.
Co
Cop py
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– If coolant pump is being renewed, renew toothed belt as well. yri
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cted
agen
Prote AG.
– Ensure proper seating of gaskets -arrows-.

– Lubricate seal for coolant pump lightly with coolant.
Note
♦ Always adhere to the sequence of work steps given below

when installing the coolant pump.
♦ This ensures that the toothed belt is correctly tensioned.
♦ The following work steps must be carried out with the aid of a
2nd mechanic.
– Set No. 1 cylinder to TDC ⇒ page 109 .

– Fit toothed belt so that it is centred and move coolant pump
into installation position.
– Mount coolant pump on cylinder head with securing bolts.

Jetta 2015 ➤
– Pre-tighten bolts in the specified sequence:

– Loosen all bolts again by one turn.
AG. Volkswagen AG d
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tion in
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Cop py
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by
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Prote AG.

Jetta 2015 ➤
– Fit torque wrench -VAS 6583- with hexagon socket (10 mm)
-item 6- to coolant pump.
– Using hexagon on coolant pump, preload coolant pump in
clockwise direction to 30 Nm using 10 mm hexagon socket
-6-, extension and torque wrench - VAS 6583- .
– For ease of use, fit torque wrench - VAS 6583- on vertically.
• Do not support torque wrench with your other hand.
• To ensure the poly V-belt is not over-tensioned, do not »push
the torque wrench again« after the specified torque has been AG. Volkswagen AG d
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• Have a second mechanic tighten securing bolts -2-, -1- and rise
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• In the meantime, you keep the torque wrench - VAS 6583- set
ce
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to specified torque.
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– Pre-load coolant pump.
erm
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– While doing so, have a second mechanic pretighten coolant
wit
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pump securing bolts in anti-clockwise direction, starting with
h re
bolts -2-, -1- and -5- (»stage 3«).
hole
spec
es, in part or in w
• By tightening securing bolts -2-, -1- and -5- to specified torque,
t to the co
the desired belt tension is reached.
• After securing bolts have been tightened initially, torque
rrectness of i
wrench - VAS 6583- can be removed.
l purpos
– Then tighten securing bolts (»stage 4«).

nf
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o
3 Bolts -2, 1, 5- 10 Nm
rm
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atio
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4 Bolts 12 Nm
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-3, 4, 5, 1, 2-
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Coolant hose schematic diagram ⇒ page 193 . t. Cop py
rig
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– Add coolant ⇒ page 199 . yri
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Torque settings
agen
Prote AG.

page 206
♦ Tightening sequence for coolant pump ⇒ page 215
2.6 Removing and installing thermostat

⇒ “2.6.1 Removing and installing thermostat for main coolant cir‐
cuit (radiator)”, page 216
⇒ “2.6.2 Removing and installing thermostat for coolant circuit of
cylinder block”, page 218
2.6.1 Removing and installing thermostat for

main coolant circuit (radiator)

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
♦ Special wrench - T10508-
Vol
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♦ Release tool - T10527-
♦ Release tool - T10527/1- rrectness of i
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Removing
nf
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– Release hose clip -4- and detach coolant hose -3-.

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– Remove bolts -arrows- and detach cover -2- from thermostat

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

Jetta 2015 ➤
– Remove thermostat using special wrench - T10508- .

– Slightly push down special wrench - T10508- and turn it in
-direction of arrow- while doing so.
Installing
– Insert thermostat ensuring that the centring pin of thermostat
is seated in guide -arrow-.
AG. Volkswagen AG d
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olksw not
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rise nte
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– Install thermostat
s au using special wrench - T10508- . ra
c
s
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le
– Slightly push down special wrench - T10508- and turn it to stop

un
pt
in -direction of arrow- while doing so.

an
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itte
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ab

pe
ility
ot
wit
– Renew seals.
, is n
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hole
– Moisten gasket with coolant.

spec
es, in part or in w

t to the co
Torque settings
rrectness of i
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - specified

torque”“ , page 208
l purpos
2.6.2 Removing and installing thermostat for

nform
ercia
coolant circuit of cylinder block

m
a
com
tio
Removing
n in
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iva
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– Unscrew bolts in the sequence -F to A-.

um
fo
en
ng
t.
yi
– Detach coolant pump from thermostat housing.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Jetta 2015 ➤
ise nte
4-cylinder
thor injection engine (1.4 l, 4V, EA211, turbocharger)
eo - Edition 07.2019
au ra
ss c
– Detach thermostat -2- from coolant pump -1-.
ce
e
nl
pt
du
an
Installing
itte
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erm
ab
ility
ot p
wit
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– Renew seals.
h re
hole
spec
– Moisten gasket with coolant.
es, in part or in w
t to the co
rrectness of i
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– Fit thermostat housing onto coolant pump.
nf
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o
• Centring pins on thermostat must be fitted in guides -arrows-
rm
m
atio
on coolant pump.
om
n in
c
– Tighten bolts for thermostat housing ⇒ page 208 .

or
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Torque settings
C py
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♦ ⇒ Fig. ““Thermostat housing to coolant pump - specified torque cop Vo
by lksw
and sequence”“ , page 208
cted agen
Prote AG.

pulley for coolant pump
Removing
– Loosen bolt -1- using counterhold - T10172- with adapters -
T10172/2- .
– Unscrew bolt and remove toothed belt pulley -2-.

Jetta 2015 ➤
Installing
– Fit toothed belt pulley:
• The grooves -1- and -2- in the camshaft are arranged asym‐
metrically.
• Cut-outs -arrows- in toothed belt pulley are also arranged
asymmetrically.
– Fit toothed belt pulley onto camshaft so that the asymmetrical
notches of the camshaft are fully centred within the cut-outs of
the toothed belt pulley.
Torque settings
page 206
2.8 Removing and installing coolant temperature sender - G62-

equipment required
AG. Volkswagen AG d
agen oes
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es, in part or in w
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tion in
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cum
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤

Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-1- on coolant expansion tank -2- briefly in
-direction of arrow-, and then close cap again (it shouldageclick
es n
into place). olksw ot g
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– Separate electrical connector: horis nte
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• Place a cloth underneath to catch anyssescaping coolant.
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es, in part or in w
– Unscrew bolt -1- and pull off coolant temperature sender -
t to the co
G62- -item 2-.
– If O-ring -3- with support ring -4- remains lodged in cylinder
rrectness of i
head, lift out O-ring with support ring using a piece of wire.
l purpos
Installing
nform
ercia
– Renew O-ring.
m
a
com
ti
– To prevent loss of coolant, insert new coolant temperature
on in
sender - G62- into cylinder head immediately.
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Torque settings en
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t.
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op
♦ ⇒ “2.3 Assembly overview - coolant temperature sender”, C py
t. rig
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page 210
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Prote AG.
2.9 Removing and installing radiator outlet
coolant temperature sender - G83-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-1- on coolant expansion tank -2- briefly in
-direction of arrow-, and then close cap again (it should click
into place).
sulation .
• Place a cloth underneath to catch any escaping coolant.

Jetta 2015 ➤ AG. Volkswagen AG d
agen oes
4-cylinder injection engine (1.4
Vol l,
ksw 4V, EA211, turbocharger) not - Edition 07.2019
g
y ua
db ran
rise tee
– Disconnect connector -1-uthon
o radiator outlet coolant tempera‐ or
ture sender - G83- -2-.ss a ac
ce
le
– Pull off retaining clip -2-, and pull radiator outlet coolant tem‐
un
pt
an
d
perature sender - G83- out of connection -3-.
itte
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rm
ab
Installing
pe
ility
ot
wit
, is n
h re
hole
spec
– Renew O-ring.
es, in part or in w
t to the co
• Insert new coolant temperature sender - G62- immediately in‐
to connection in order to avoid loss of coolant.
– Install front noise insulation ⇒ General body repairs, exterior;
rrectness of i
l purpos
sulation .
nform
mercia
a
com
tion in
r
te o
thi
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iva
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cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes”, page 223
⇒ “3.2 Removing and installing coolant pipes”, page 223
3.1 Assembly overview - coolant pipes
1 - Coolant hose
2 - Coolant pipe
❑ Clipped onto intake
manifold (bottom)
❑ To remove, remove in‐
take manifold
⇒ page 274
AG. Volkswagen AG d
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4 - Coolant hose aut
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5 - Coolant hose
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6 - Coolant line
itte
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❑ Clipped onto intake
ility
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manifold (top)
wit
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7 - Coolant hose
hole
spec
8 - Coolant hose
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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Cop py
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Prote AG.
3.2 Removing and installing coolant pipes

3. Coolant pipes 223

Jetta 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
Removing d by
V gu
ara
ise nte
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CAUTION aut ra
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nl
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ility
scalding.
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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t.
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Cop py
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pyri by
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes Jetta 2015 ➤
olksw not
V
4-cylinder ed binjection engine (1.4 l, 4V, EA211,guturbocharger)
y ara - Edition 07.2019
ris nte
tho eo
– Clamp off coolant hoses
ss a at coolant pipe with hose clamps
u ra
c
-3094- .
ce
le
un
pt
an
– Release hose clips -arrows- and detach coolant hoses.
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
– Lay intake manifold -1- on the workbench as shown.
ss o
cial p
f
– Place e.g. a block of wood -2- under the intake manifold as an
inform
underlay.
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
iva
o
pr
c
To avoid damaging the intake manifold and coolant pipe, this pro‐
um
r
fo
cedure must be carried out very carefully!
en
ng
t.
yi Co
Cop py
t. rig
– Insert a flat-blade screwdriver into the slot -arrow 1-.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Carefully push the flat-bade screwdriver in

-direction of arrow 2- and lift the coolant pipe -4- in
-direction of arrow 3- until it comes free from the retainer.
– Continue to lift the coolant pipe -1- in -direction of arrow- until

it comes free of the retainer -2-.
3. Coolant pipes 225

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Jetta 2015 ➤ wage
n AG does
olks not
d b - Edition 07.2019
y V gu
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Installing au
t ra
c
ss
– First push the coolant pipe onto the mounting -1- until it en‐
ce
le
un
pt
gages.
an
d
itte
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rm
ab
– Then push the coolant pipe onto the mounting -2- until it en‐
pe
ility
gages.
ot
wit
, is n
h re
– Check that the coolant pipe has properly engaged by pulling
hole
on it.
spec
es, in part or in w
t to the co
• Renew seals and O-rings.
rrectness of i
l purpos
nform
ercia

m
a
com
tio
Torque settings
n in
r
te o
thi
♦ ⇒ “3.1 Assembly overview - coolant pipes”, page 223
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.

Jetta 2015 ➤
4 Radiator, radiator fan

olkswagen AG
en AG. V
⇒ “4.1 Assembly overview - radiator/radiator
olks
wag fan”, pagedo227
es n
o V t gu
by a
⇒ “4.2 Assembly overviewise - radiator cowl and radiator fan”, pageante
d r
or
229 au
th eo
ra
ss c
⇒ “4.3 Removing and installing radiator”, page 229
ce
le
un
pt
an
d
⇒ “4.4 Removing and installing water radiator for charge air cool‐
itte
y li
ing circuit”, page 231
rm
ab
pe
ility
⇒ “4.5 Removing and installing radiator cowl”, page 233
ot
wit
, is n
h re
⇒ “4.6 Removing and installing radiator fan V7 ”, page 235
hole
spec
es, in part or in w
⇒ “4.7 Removing and installing radiator fan 2 V177 ”, page 235
t to the co
4.1 Assembly overview - radiator/radiator
fan
rrectness of i
l purpos
Note
nform
ercia
The arrows on the coolant pipes and on the ends of the hoses
m
a
must be aligned with each other.
com
tion in
r
te o
thi
s
iva
do
1 - Bolts
r
rp
cum
fo
❑ For air conditioning con‐

en
ng
t.
yi
denser.
Co
Cop py
t. rig
❑ 5 Nm opyri
gh by
Vo
ht
c lksw
2 - Condenser
by
cted agen
Prote AG.
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ;
Refrigerant circuit; Re‐
moving and installing
condenser
3 - Radiator for charge air cool‐
ing circuit
⇒ page 231
4 - Radiator mounting
5 - Refrigerant lines
❑ To condenser
6 - O-ring
❑ For refrigerant lines
7 - Rubber mounting
❑ Bottom of radiator in
lock carrier
8 - O-ring
❑ Connection, radiator for
charge air cooling circuit
4. Radiator, radiator fan 227

Jetta 2015 ➤
9 - Retaining clip
❑ Connection for coolant
hose, charge air cooler
10 - Coolant hose
❑ On radiator for charge air cooling circuit
❑ Lift retaining clip to remove
❑ Connect ⇒ page 228
11 - Retaining clip wage
es n
lks ot g
Vo
12 - Radiator outlet coolant temperature sendered- G83-
by ua
ran
ir s tee
❑ Removing and installing ⇒ page 221uth o
or
a ac
ss
13 - O-ring
ce
le
un
pt
an
d
itte
y li
erm
14 - Coolant hose
ab
ility
ot p
wit
is n
h re
ole,
spec
15 - O-ring
t to the co
❑ Connection, radiator
rrectne
16 - Retaining clip
17 - Bolts
ss o
❑ 5 Nm
cial p
f inform
18 - Radiator for engine coolant
mer
atio
om
n
c
i
or
n thi
te
sd
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19 - Coolant hose
iv
o
pr
cum
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en
ng
t.
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Co
Cop py
t. rig
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pyri by
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by
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Connecting coolant hose with plug-in connector Prote AG.
– Remove old O-ring -2- in coolant hose -3-.

– Moisten new O-ring with coolant and insert into coolant hose.
– Push coolant hose into connection -1- until it audibly engages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.

Jetta 2015 ➤
4.2 Assembly overview - radiator cowl and radiator fan
1 - Radiator cowl
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
⇒ page 233 d byV gu
ar
e an
ris tee
2 - Bolt tho or
au ac
❑ Radiator cowl
ss
to radiator
ce
le
un
❑ 5 Nm
pt
an
d
itte
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3 - Bolt
rm
ab
pe
ility
❑ Radiator cowl to radiator
ot
wit
, is n
h re
hole
⇒ page 227
spec
es, in part or in w
4 - Radiator fan 2 - V177-
t to the co
⇒ page 235
rrectness of i
5 - Radiator fan - V7-
l purpos

⇒ page 235
nform
ercia
6 - Bracket
m
❑ Coupling point
a
com
tion in
7 - Bolt
r
te o
thi
s
❑ Radiator cowl to radiator
iva
do
r
rp
um
fo
en
g
⇒ page 227
n
t.
yi Co
Cop py
8 - Bolt ht. rig
rig ht
py by
❑ 5 Nm co Vo
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Prote AG.
4.3 Removing and installing radiator

♦ Refractometer - T10007-

AG. Volkswagen AG d
agen oes
olksw not
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Jetta 2015 ➤ orise nte
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h
s a turbocharger) - Edition 07.2019
ut ra
c
s
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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
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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Release retaining clip -arrow-.
– Pull off coolant hose -1- from top of radiator.

Jetta 2015 ➤
– Remove securing bolts -arrows- of radiator -1-, and remove

radiator upwards.
Installing
– Install radiator cowl ⇒ page 233 .
– Fill with new coolant ⇒ page 203 .
Torque settings
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 227
♦ ⇒ “4.2 Assembly overview - radiator cowl and radiator fan”,
page 229
4.4 Removing and installing water radiator for charge air cooling circuit
Volkswa n AG. gen AG
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Special tools and workshop ris
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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.
♦ Refractometer - T10007A-

Jetta 2015 ➤
Note
♦ Hose connections are secured with spring-type clips. In case

of repair, only use spring-type clips.
AG. Volkswagen AG d
agen
♦ Hose clip pliers - VAS
Vol 6340- are recommended to
ksw
oes
not install
spring-type clips.
se
db
y g ua
ran
ri tee
o
♦ When installing
aut
h
coolant hoses, route tension-free so that they
or
a
do not come
ss into contact with other components (observe c
ce
e
markings on coolant connection and hose).

nl
pt
du
an
itte
y li
erm
– Remove noise insulation or skid plate ⇒ General body repairs,
ab
ility
ot p
wit
noise insulation .
, is n
h re
hole
spec
es, in part or in w
– Remove radiator cowl with radiator fan ⇒ page 233 .
t to the co
– Removing radiator ⇒ page 229 .
rrectness of i
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
l purpos
cover .
– Lift retaining clip -arrow-, and remove upper right hose from nf
ercia
water radiator for charge air cooling circuit.

orm
m
atio
om
n in
or c
thi
te
sd
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rp
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Undo and remove coolant pump bolts -arrows- of the radiator

support.

Jetta 2015 ➤
Vehicles with air conditioning system

– Undo and remove condenser bolts -arrows-.
– Secure condenser to lock carrier.
Note
Make sure that the coolant lines/hoses are not excessively

stretched, kinked or bent.

– Pull bottom of radiator for charge air cooling circuit out of
mounting.
– Remove radiator for charge air cooling circuit downwards.
Installing
Install in reverse order of removal. The following should be ob‐
served: gen AG
. Volkswagen AG
d a oes
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– Add coolant ⇒ page 197 . y Vol gu
b ara
ed nte
ris
Torque settings tho eo
au ra
c
ss
ce
e
nl
pt
du
an
Threaded connection on 5 Nm
itte
y li
lock carrier
erm
ab
ility
ot p
♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 227
wit
, is n
h re
hole
spec
es, in part or in w
noise insulation
t to the co
♦ Front bumper; Assembly overview - bumper cover ⇒ General
body repairs, exterior; Rep. gr. 63 ; Front bumper; Assembly
rrectness of i
overview - bumper cover
l purpos
4.5 Removing and installing radiator cowl
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
sd
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
Removing
– Release spring-type clips -3-, and remove intake hose -1-.
– Unclip cover of intake air duct -2- -arrows-, and remove it.
– Press catches of lower part of intake air duct, and remove in‐
take air duct towards rear.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
u ra
– Unscrew bolts of air duct on lock carrier -arrows-, and remove
ss a c
air duct -1-.
ce
e
nl
pt
du
an
itte
y li
CAUTION
erm
ab
ility
ot p
Risk of injury to hands caused radiator fan which may start au‐
wit
, is n
tomatically at any time.
h re
hole
– Do not grasp into the radiator fan when disconnecting con‐
spec
nector.
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove bolts -1- at top.
nf
ercia
or
Note
m
m
atio
om
n in
c
The left bolt is located below the coolant union.

or
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
yi
sulation .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release connector -arrow- and pull off.

– Unscrew bolts -2- from below, and remove radiator cowl down‐
wards.
Installing
Torque settings
page 229
noise insulation

Jetta 2015 ➤
4.6 Removing and installing radiator fan - AG. Volkswagen

AG do
V7-
n
wage es n
Volks ot g
y b ua
ed ran
ris tee
CAUTION tho
or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
nector.
ility
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wit
is n
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Removing
ole,
spec
• Fit all cable ties in the original position when installing.
t to the co
– Separate electrical connector -arrow-.
rrectne
– Unscrew bolts -1-, and remove radiator fan - V7- .
ss
Installing
o
cial p
f in
form
mer
atio
om
n
c
i
Torque settings
or
n thi
te
sd
a

iv
o
pr
c
page 229
um
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
by
4.7 Removing and installing radiator fan 2 - copy Vo
by lksw
cted agen
V177-
Prote AG.
CAUTION
nector.
Removing
• Fit all cable ties in the original position when installing.
– Unscrew bolts -2-, and remove radiator fan - V177- .
Installing
Torque settings
page 229

Jetta 2015 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 236
⇒ “1.2 Removing and installing turbocharger”, page 239
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 245
⇒ “1.4 Removing and installing connection for turbocharger”,
page 248
1.1 Assembly overview - turbocharger

⇒ “1.1.1 Assembly overview - turbocharger, version 1”,
page 236
⇒ “1.1.2 Assembly overview - turbocharger, version
olks
w2”,
age es n
ot g
page 237 d byV ua
ran
e
ris tee
⇒ “1.1.3 Assembly overview - lines on turbocharger”,
ut
ho page 238 or
a ac
ss
1.1.1 Assembly overview - turbocharger, version 1
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Turbocharger
ility
ot p
wit
, is n
h re
⇒ page 239
hole
spec
2 - Bolt
es, in part or in w
t to the co
❑ 8 Nm
3 - Connection
rrectness of i
⇒ “1.4 Removing and in‐
l purpos
stalling connection for

turbocharger”,
page 248
nform
mercia
4 - O-ring
at
om
io

n
c
in t
or
his
e
❑ Before installing, mois‐

at
do
riv
ten lightly with clean en‐

p
cum
gine oil
for
en
ng
t.
yi Co
5 - Seal t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
6 - Heat shield cted agen
Prote AG.
7 - Bolt
❑ 25 Nm
8 - Bolt or nut
❑ 8 Nm
9 - Nut
❑ 14 Nm
10 - Bolt
❑ 9 Nm
236 Rep. gr.21 - Turbocharging/supercharging

Jetta 2015 ➤
11 - Retaining clip
12 - Release lever
13 - Lock nut
❑ Secure with sealing paint
❑ 6 Nm
14 - Charge air pressure controller - V465-
❑ Consider different possible versions of charge pressure positioner
1.1.2 Assembly overview - turbocharger, version 2
1 - Bolt
❑ 25 Nm
2 - Bolt or nut
❑ 8 Nm
3 - Heat shield
4 - Turbocharger
⇒ page 239
5 - Nut
AG. Volkswagen AG d
❑ Renew after removal lksw
agen oes
not
Vo gu
❑ 14 Nm d by ara
rise nte
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6 - Retaining clip auth
ra
ss c
ce
e
nl
pt
du
an
7 - Release lever
itte
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erm
ab
8 - Control rod
ility
ot p
wit
9 - Lock nut
, is n
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hole
❑ Secure with sealing
spec
paint
es, in part or in w
t to the co
❑ 6 Nm
10 - Retaining clip rrectness of i
l purpos
11 - Release lever
12 - Bolt
nform
ercia

m
at
❑ 9 Nm
om
ion
c
in t
r
13 - Charge air pressure con‐

o
his
te
troller - V465-
a
do
priv
❑ Consider different pos‐

um
for
en
g
sible versions of charge pressure positioner

n
t.
yi Co
op
C py
t. rig
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yri by
14 - Bolt cop Vo
by lksw
cted agen
❑ 8 Nm Prote AG.
15 - Connection
❑ Removing and installing ⇒ “1.4 Removing and installing connection for turbocharger”, page 248
1. Turbocharger 237
Jetta 2015 ➤
16 - O-ring
17 - Seal
1.1.3 Assembly overview - lines on turbocharger

AG. Volkswagen AG d
agen oes
olksw not
1 - Oil return line ed byV gu
ara
ris nte
2 - O-ring aut
ho eo
ra
s c
❑ Renew after removal s
ce
le
un
pt
3 - Bolt
an
d
itte
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❑ 9 Nm
rm
ab
pe
ility
ot
4 - O-ring
wit
, is n
h re
hole
spec
5 - Bolt
es, in part or in w
t to the co
❑ 9 Nm
6 - Oil supply line
rrectness of i
7 - O-ring
l purpos

8 - Bolt
nform
ercia
❑ 9 Nm
m
a
com
ti
9 - Bolt
on in
r
te o

thi
s
iva
do
❑ 5 Nm
r
rp
cum
fo
10 - O-ring
en
ng
t.
yi Co
op
❑ If damaged, renew C py
ht. rig
crankcase breather rig ht
py by
hose
co Vo
by lksw
cted
⇒ Item 11 (page 238)
agen
Prote AG.
❑ Before installing, mois‐

ten lightly with clean en‐
gine oil
11 - Hose
tion.
12 - Bolt
❑ 5 Nm
13 - O-ring
❑ If damaged, renew crankcase breather hose ⇒ Item 11 (page 238)
❑ Before installing, moisten lightly with clean engine oil
14 - Turbocharger
15 - Seal
16 - Coolant lines
❑ Supply and return

Jetta 2015 ➤
17 - Bolt
❑ 8 Nm
18 - O-ring
19 - Bolt
❑ 9 Nm
1.2 Removing and installing turbocharger

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
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erm
ab

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
♦ Socket T 30 - T10405-
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.
1. Turbocharger 239
Jetta 2015 ➤
♦ Ratchet insert tool 1/4" - VAS 6234-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
♦ Release tool - T10527/1-

wit
, is n
h re
Removing
hole
spec

es, in part or in w
t to the co

– Fit all heat shield sleeves in the same place when installing.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
Note
♦ If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just re‐
new the turbocharger. To avoid any subsequent damage, the
following work must be carried out:
♦ Check air filter housing, air filter element and air inlet hoses
for contamination.
♦ Check the whole charge air path and charge air cooler for for‐
eign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the charge
air cooler.

shaft.
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
es, in part or in w
-3-.
t to the co
– If necessary, remove electric vacuum pump ⇒ Brake system;

Rep. gr. 47 ; Vacuum system; Assembly overview - electric
vacuum pump .
rrectness of i
l purpos
return line -2-.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Disconnect connectors -1- and -2-:

p
cum
for
en
g
1 - For coolant temperature sender - G62-

n
t.
yi Co
Cop py
2 - For charge pressure positioner - V465-
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Turbocharger 241
Jetta 2015 ➤

verter.
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
coal filter.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6234- and socket T 30 - T10405- .

wage es n
yV
olks ot g Jetta 2015 ➤
b u
ir se
d (1.4 l, 4V, EA211, turbocharger) -arEdition
an
tee 07.2019
utho or
a ac
– If fitted, release hose clip -2-, and remove
ss coolant hose.
ce
e
nl
pt
– Remove bolts -arrows- and pivot coolant lines -1- to right side.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts and nuts -arrows-, and remove heat shield -1-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew nuts -arrows- and remove turbocharger.
1. Turbocharger 243
Jetta 2015 ➤ gen AG
. Volkswagen AG
does
swa
4-cylinder injection engine (1.4 l, 4V, EA211, yturbocharger)
Volk - Edition 07.2019 not
gu b ara
ed nte
ris
Installing au
tho e or
ac
ss
ce
e
nl
pt
du
an
– Insert screwdriver -2- in recess -arrow- on turbocharger.
itte
y li
erm
ab
– Lever out seal -1-.
ility
ot p
wit
, is n
– Renew seals, O-rings and securing nuts of cylinder head.
h re
hole
– Fill turbocharger with engine oil at connection for oil supply
spec
es, in part or in w
line.
t to the co
– Restore electrical connections and observe routing ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
rrectness of i
– Install electric vacuum pump ⇒ Brake system; Rep. gr. 47 ;
Vacuum system; Assembly overview - electric vacuum pump .
l purpos
– Attach all heat-shielding sleeves in the same places when in‐

stalling.
nf
ercia
orm
m
atio
om
n in
c
– Check oil level.

or
thi
te
sd
a
– After installing turbocharger, run engine for about 1 minute at

iv
o
r
rp
cu
idling speed to ensure that oil is supplied to turbocharger. It is
o
m
f
important not to operate the engine at higher speeds at this
en
ng
t.
yi
point.
Co
Cop py
ht. rig
After installing new parts (engine/short engine, cylinder head or
rig ht
py by
o Vo
turbocharger) by c lksw
cted agen
Prote AG.
• Oil pressure regulation should be limited to the high pressure
stage for about 1000 km, provided this function is available in
the engine control unit.
– Switch on ignition.
– Select following menu option: if available, select function 0001
- Engine run-in oil pressure .
Torque settings
♦ ⇒ Fig. ““Installing air ducts with screw-type clips”“ ,
page 253

Jetta 2015 ➤
1.3 Removing and installing charge pres‐

sure positioner - V465-
⇒ “1.3.1 Removing and installing charge pressure positioner
V465 , version 1”, page 245
⇒ “1.3.2 Removing and installing charge pressure positioner
V465 , version 2”, page 246
1.3.1 Removing and installing charge pres‐

sure positioner - V465- , version 1
Note
♦ Different versions of charge pressure positioner have been in‐

stalled.
♦ They have different securing points.
♦ Before installing, visually check which version applies for the
purposes of repair.

♦ Locking tool - T40265-
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
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rm
ab
pe
ility
ot
wit
, is n
h re
Removing
hole
spec

es, in part or in w
t to the co

sulation .
rrectness of i
– Detach heat shield for right drive shaft.

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.
1. Turbocharger 245
Jetta 2015 ➤

– Pull off securing clip -2- using locking tool - T40265- .
– Remove bolts -arrows- and detach charge pressure positioner
- V465- .
Installing
Always renew securing bolts and the securing clip.
Note
There may be different types of charge air pressure controllers

installed.
Charge air pressure controller without adjustable linkage

– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; Guided func-
tions .
Charge air pressure controller with adjustable linkage
olks
wage es n
ot g
V
by ua
– Fit thread of charge pressure positioner -V465-
ris
ed at central po‐ ran
tee
sition in joint element. ut
ho
or
a ac
ss
– Adjust charge air pressure controller - V465- : ⇒ Vehicle diag‐
ce
e
nl
nostic tester Select 01 - Adjust charge air pressure
pt
du
an
itte
controller V465 in Guided functions .
y li
erm
ab
ility
– Adjust to specified value by turning linkage. For specified val‐
ot p
wit
ue, see ⇒ Vehicle diagnostic tester.
, is n
h re
hole
– Tighten lock nut to 6 Nm and secure with sealing paint.
spec
es, in part or in w
Torque settings
t to the co
rrectness of i
l purpos
noise insulation
nf
ercia

orm
m
atio
m
1.3.2 Removing and installing charge pres‐

o
n in
or c
thi
sure positioner - V465- , version 2

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
♦ Different versions of charge pressure positioner have been in‐
p by
o Vo
by c lksw
stalled. cted agen
Prote AG.
♦ They have different securing points.

♦ Before installing, visually check which version applies for the
purposes of repair.

Jetta 2015 ➤
♦ Locking tool - T40265-
♦ Socket T 30 - T10405- agen AG. Volkswagen AG do

lksw es n
o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing rrectness of i

l purpos

nform
ercia

sulation .
m
at
om
ion

c
in t
or
his
te
– Detach heat shield for right drive shaft.

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.
1. Turbocharger 247
Jetta 2015 ➤

6234- and socket T 30 - T10405- .
– Pull off securing clips -3-, and remove operating lever -4- using
locking tool - T40265- .
– Disconnect connector -2-, and remove charge pressure posi‐
tioner - V465- -1-.
Installing
Always renew securing bolts and the securing clip.
Charge air pressure controller without adjustable linkage
– Adapt engine control unit - J623- to charge pressure positioner
- V465- using ⇒ Vehicle diagnostic tester; Guided func-
tions .
Charge air pressure controller with adjustable

gen AG
. Volkswagelinkage
n AG
a does
lksw n
– Fit thread of chargedpressure
by
Vo positioner -V465- at central
ot g
ua po‐
sition in joint element.
o
ir se
ran
te
th eo
– Adjust charge au ra
ss air pressure controller - V465- : ⇒ Vehicle diag‐ c
nostic tester Select 01 - Adjust charge air pressure
ce
le
un
pt
controller V465 in Guided functions .

an
d
itte
y li
erm
ab
– Adjust to specified value by turning linkage. For specified val‐

ility
ot p
ue, see ⇒ Vehicle diagnostic tester.

wit
is n
h re
– Tighten lock nut to 6 Nm and secure with sealing paint.

ole,
spec
Torque settings
t to the co

rrectne

ss
noise insulation
o
cial p
f in

form
mer

atio
om
n
c
i
or
1.4 Removing and installing connection for

thi
te
sd
a
turbocharger
iv
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.

Jetta 2015 ➤
♦ Socket T 30 - T10405-
♦ Ratchet insert 1/4 inch - VAS 6234-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove resonator for intake air

hole
⇒ “3.3 Removing and installing resonator for intake air”, page

spec
272 .
es, in part or in w
t to the co
– Remove air pipe

⇒ “2.5 Removing and installing air pipe”, page 257 .
rrectness of i
– Release and pull off electrical connector -1- on coolant tem‐

perature sender - G62- .
l purpos
Vehicles with charge pressure sender - V465- , version 1:

nf
ercia
– Release and pull off connector -2- on charge pressure posi‐

orm
tioner - V465- .
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.
1. Turbocharger 249
Jetta 2015 ➤
Vehicles with charge pressure sender - V465- , version 2:

– Release and pull off connector -2- on charge pressure posi‐
tioner - V465- .
Continued for all vehicles:
– Lay wiring harness to one side.
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Open hose clip -1- and push coolant hose -2- to one side.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Unscrew bolt -arrows- and remove connection -1-.

ion
c
in t
or
Installing:
his
ate
do
riv
Install in reverse order of removal, observing the following:

p
cum
for
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
♦ Renew seals, O-rings and securing nuts of cylinder head. cted agen
Prote AG.
♦ Before installing, lightly moisten O-rings with clean engine oil.

♦ Secure hose connections with hose clips according to pro‐
duction standard ⇒ Electronic parts catalogue (ETKA) .
Specified torques
⇒ “1.1 Assembly overview - turbocharger”, page 236

Jetta 2015 ➤
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 251
⇒ “2.2 Removing and installing charge air cooler”, page 253
⇒ “2.3 Removing and installing charge pressure sender GX26 ”,
page 255
⇒ “2.4 Checking charge air system for leaks”, page 256
⇒ “2.5 Removing and installing air pipe”, page 257
2.1 Assembly overview - charge air system
Note
Before performing any checks or any repair work, make sure that all air pipes, air hoses and vacuum lines are
firmly seated and leak-tight. G. Volkswagen A AG do
agen es n
olksw ot g
yV ua
db ran
ise
1 - O-ring tho
r tee
or
au ac
ss
ce
le
❑ Moisten O-ring with

un
pt
an
d
clean engine oil before

itte
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installing
erm
ab
ility
ot p
2 - Union
wit
is n
h re
3 - O-ring
ole,
spec
t to the co
clean engine oil before
installing
rrectne
4 - Air intake pipe
s

s o
⇒ page 257
cial p
f inform
5 - Charge air pressure sender

mer
- GX26-
atio
om
❑ Consisting of
c
i
or
n thi
te
Charge pressure sender

sd
iva
o
r
- G31-
p
cum
r
fo
en
ng
t.
yi
Intake air temperature
Co
op py
sender - G42- t. C rig
gh ht
pyri by
co Vo
by lksw
cted
⇒ page 255
agen
Prote AG.
6 - O-ring
❑ Not sold separately
❑ If damaged, renew
charge pressure sender
- GX26-
7 - O-ring
clean engine oil before installing
8 - Bolt
❑ Thread-cutting
2. Charge air system 251

Jetta 2015 ➤
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque
❑ 7 Nm
9 - Retaining clip
❑ For air intake pipe
10 - Throttle valve module - GX3-
❑ Consisting of
Throttle valve module - J338-
Throttle valve drive for electronic power control - G186-
Throttle valve drive angle sender 1 for electronic power control - G187-
11 - Seal
AG. Volkswagen AG d
agen oes
12 - Intake manifold olksw not
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d b ara
Removing and installing ⇒ hpage
rise 274 nte
t o eo
au ra
s c
13 - Seal s
ce
e
nl
pt
❑ Renew
du
an
itte
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14 - Sealing lip
erm
ab
ility
ot p

wit
, is n
❑ Moisten O-ring with clean engine oil before installing

h re
hole
15 - Coolant hose spec

es, in part or in w
t to the co
16 - Clip
17 - Charge air cooler
rrectness of i

l purpos

18 - Bolt
nform
ercia
❑ Thread-cutting
m
at
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque
om
ion
c
❑ 15 Nm
in t
or
his
ate
19 - Coolant hose
do
priv
cum
or
20 - Clip
f
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ng
t.
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op
21 - Coolant hose C py
t. rig
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yri by
22 - Clip cop Vo
by lksw
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Prote
23 - Bolt
AG.

24 - O-ring
❑ Renew
25 - Intake manifold sender - GX9-
❑ Consisting of
Intake air temperature sender 2 - G299-
Intake manifold pressure sender - G71-


Jetta 2015 ➤
26 - Seal
❑ Qty. 4
Installing air ducts with screw-type clips

Note
Hose unions and air intake pipes and hoses must be free of oil
and grease before installation.
Torque settings
AG. Volkswagen AG d
agen oes
ksw
Component byV
ol Specified torque not
gu
d ara
e
Hose clip 1 -a- = 13 horis
mm wide 5.5 Nm nte
eo
ut ra
Hose clip 2 -b-s = 9 mm wide
s a
3 Nm c
ce
e
nl
pt
du
an
2.2 Removing and installing charge air cool‐
itte
y li
erm
ab
er
ility
ot p
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

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

Jetta 2015 ➤
Removing
– Open clip -1- and push hose -arrow- to one side.
– Disconnect connector -1-.
– Remove air conditioner compressor from bracket -arrows- and

tie up ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner n AG. Volkswagen AG do
kswage es n
compressor; Removing and installing air conditioner compres‐ by Vo l ot g
ua
sor from and to bracket . ir se
d ran
te
tho eo
ss
au ra
c
ce
e
– Clamp off coolant hoses at charge air cooler with hose clamps
nl
pt
du
an
-3094- .
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Release hose clip -1- and remove coolant hose.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
– Pull charge air cooler -1- evenly towards front (in

-direction of arrow-) out of intake manifold.
Installing
– Fit sealing lip -1- in -direction of arrow- onto charge air cooler
-2-.
– Insert new gasket into groove on intake manifold.
– Tighten bolts -arrows- alternately and diagonally working from

centre outwards.
– Install hose clips -1-.
AG. Volkswagen AG d
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agen oes
not
Vo gu
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If there are minor dents in the fins, refer to ⇒ pagehor5is .
e nte
eo
aut ra
ss c
ce
e
nl
pt
du
– Check coolant level ⇒ page 203 . an

itte
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erm
ab
Torque settings ility
ot p
wit
, is n

h re
hole
spec
♦ Removing air conditioner compressor from and fitting to brack‐

es, in part or in w
et ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner

t to the co
compressor; Removing air conditioner compressor from and

fitting to bracket .
rrectness of i
2.3 Removing and installing charge pres‐

l purpos
sure sender - GX26-

nform
Charge pressure sender - GX26- consists of:

mercia
♦ Charge pressure sender - G31-

at
om
ion
c
♦ Intake air temperature sender - G42-

in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
Removing
– Release fasteners -arrows-, and remove charge pressure
sender - GX26- .
Installing
• Renew O-ring.
Note
If the retaining tabs broke off during removal, the sender can be
mounted using two securing bolts ⇒ Electronic parts catalogue
(ETKA) .
Torque settings AG. Volkswagen AG d

agen oes
lksw not
Component Specified
d by
Vo
torque gu
ara
ise nte
r
Charge pressure sender - utho 3 Nm eo
ra
GX26- ss a c
ce
le
un
pt
an
d
2.4 Checking charge air system for leaks

itte
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rm
ab
pe
ility
ot
wit
, is n
♦ Charge air system tester - V.A.G 1687-
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
Procedure
do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Connect adapter - V.A.G 1687/15- with adapter -V.A.G C py
t. rig
1687/11- to turbocharger.
gh ht
pyri by
Vo
o
by c lksw
– Connect hose -1- of charge air system tester -V.A.G 1687- to cted agen
Prote AG.
adapter.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Jetta 2015 ➤
aut 4-cylinder injection engine (1.4 l, 4V, EA211, ra turbocharger) - Edition 07.2019
ss c
ce
e
nl
pt
Prepare charge air system tester - V.A.G 1687- as follows:
du
an
itte
y li
– Completely unscrew pressure regulating valve -2-, close erm
ab
ility
valves -3- and -4-.
ot p
wit
, is n
• To turn the pressure regulating valve -2- the knob must be
h re
hole
pulled upwards.
spec
es, in part or in w
– Connect charge air system tester - V.A.G 1687- to com‐
t to the co
pressed air -1- via commercial adapter.
rrectness of i
Note
l purpos
If there is water in the inspection glass, drain it via the water drain
plug -6-.
nform
mercia
at
– Open valve -3-.
om
ion
c
in t
r

o
his
ate
do
riv
Risk of damage because pressure is set too high.

p
cum
for
The pressure must not exceed 0.5 bar.
en
ng
t.
yi Co
op py
– Adjust pressure to 0.5 bar with pressure control valve -2-.
. C rig
ht ht
rig by
py
– Open valve -4- and wait until test circuit is full. If necessary,
co Vo
by lksw
cted
adjust pressure to 0.5 bar.
agen
Prote AG.
– Check charge air system for leaks by hearing, touching, with

commercially available leak detector spray or using ultrasonic
tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating
instructions
♦ Before removing the adapter, release pressure in the test cir‐
cuit by pulling off hose coupling.

• Renew seal and O-rings.
Torque settings
♦ ⇒ Fig. ““Installing air ducts with screw-type clips”“ , page 253
2.5 Removing and installing air pipe


Jetta 2015 ➤
Removing
wage es n
– Remove air filter housing y V⇒ page 271 .
olks ot g
ua
b
ed ran
– Free air hose fromthoair
r pipe.
is tee
u or
a ac
– Detach connector
ss from charge pressure sender - GX26- .
ce
e
nl
pt
– Release fasteners -arrows- using release tools - T10527- and

du
an
itte
-T10527/1- .
y li
erm
ab
ility
– Remove air pipe -1-.

ot p
wit
, is n
– Release fasteners using release tool - T10527- , and remove

h re
hole
air intake pipe.

spec
es, in part or in w
– Seal open connections using clean plugs from engine bung

t to the co
set - VAS 6122- .

Installing
rrectness of i

l purpos
• Renew seals after removal.

nform
ercia
• Before installing, lightly coat seals with clean engine oil.

m
• Renew any retaining tabs that have been damaged.

at
om
ion
c
• If retaining tabs of charge pressure sender - GX26- have bro‐

in t
or
his
e
ken off, sensor can be secured using 2 bolts ⇒ Electronic parts

at
do
riv
catalogue (ETKA) .
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 259
1.1 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment

1 - N205-
⇒ page 153 AG. Volkswagen AG d
agen oes
olksw not
V gu
2 - Exhaust camshaft control d by ara
ise nte
valve 1 - N318- hor eo
aut ra
❑ Installed in vehicles with ss c
adjustable exhaust
ce
le
un
pt
camshaft only
an
d
itte
y li
erm
ab
⇒ page 154
ility
ot p
wit
is n
3 - Lambda probe 1 before cat‐
h re
ole,
alytic converter - GX10-
spec
❑ Consisting of:
t to the co
Lambda probe - G39-
Lambda probe heater -
rrectne
Z19-
s
s o
⇒ page 298
cial p
f inform
4 - Lambda probe 1 after cata‐
mer
lytic converter - GX7- atio

om
n
c
❑ Consisting of:
i
or
n thi
te
sd
a
Lambda probe after cat‐

iv
o
pr
alytic converter - G130-

um
r
fo
en
ng
t.
yi
Lambda probe 1 heater
Co
Cop py
after catalytic converter -
t. rig
gh ht
yri
Z29- p by
o Vo
by c lksw
cted agen
❑ Removing and installing Prote AG.
⇒ page 298
5 - Charge air pressure con‐
troller - V465-
6 - Exhaust cam actuator for cylinder 2 - N587-
❑ Not fitted
7 - Exhaust cam actuator for cylinder 3 - N595-
❑ Not fitted
8 - Inlet cam actuator for cylinder 2 - N583-
❑ Not fitted
9 - Inlet cam actuator for cylinder 3 - N591-
❑ Not fitted
1. Injection system 259

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Jetta 2015 ➤ ut
ho eo
ra
a
4-cylinder injection engine (1.4 l, 4V,
s EA211, turbocharger) - Edition 07.2019
s c
ce
le
un
pt
an
d
itte
y li
erm
❑ Installed in vehicles with adjustable exhaust camshaft only
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
12 - Engine control unit - J623-
rrectne
13 - Radiator outlet coolant temperature sender - G83-
ss o
cial p
14 - Throttle valve module - GX3-
f inform
❑ Consisting of:
mer
atio
m
Throttle valve module - J338-

o
n
c
i
or
n thi
e
Throttle valve drive for electronic power control - G186-

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Throttle valve drive angle sender 2 for electronic power control - G188- C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
15 - Charge air pressure sender - GX26-
Prote AG.
❑ Consisting of:
Charge pressure sender - G31-
Intake air temperature sender - G42-

16 - Intake manifold sender - GX9-
❑ Consisting of:
Intake air temperature sender 2 - G299-
Intake manifold pressure sender - G71-

17 - Charge air cooling pump - V188-
18 - Ignition coils with output stages
♦ Ignition coil 1 with output stage - N70-
Overview of fitting locations – engine, intake side
260 Rep. gr.24 - Mixture preparation - injection

Jetta 2015 ➤
1 - Knock sensor 1 - G61-

❑ Assembly overview
⇒ page 314
2 - Oil pressure switch for re‐
duced oil pressure - F378-
⇒ page 189
3 - Fuel pressure sender -
G247-
⇒ page 263
4 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ To remove, remove in‐
take manifold
5 - Injectors
♦ Injector, cylinder 1 - N30-
⇒ page 263
6 - Fuel pressure regulating
valve - N276-
❑ On high-pressure pump AG. Volkswagen AG d
agen oes
7 - Engine speed sender - olksw not
y V gu
G28- rise
d b ara
nte
o eo
❑ Assembly overview auth
ra
⇒ page 314 ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Overview of fitting locations - engine, exhaust side

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.
1. Injection system 261

Jetta 2015 ➤
1 - Oil level and oil temperature

sender - G266-
⇒ page 179
G62-
⇒ page 220
3 - Oil pressure switch - F1-
⇒ page 188
AG. Volkswagen AG d
agen oes
4 - Valve for oil pressure con‐ Volksw not
gu
trol - N428- d by ara
ise nte
r
❑ Removing and installing aut
ho eo
ra
⇒ page 191 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
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Jetta 2015 ➤
aut 4-cylinder injection engine (1.4 l, 4V, EA211, ra turbocharger) - Edition 07.2019
ss c
ce
e
nl
pt
du
an
2 Injectors
itte
y li
erm
ab
ility
ot p
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 263
wit
, is n
h re
⇒ “2.2 Removing and installing fuel rail”, page 264
hole
spec
⇒ “2.3 Removing and installing injectors”, page 264
es, in part or in w
t to the co
⇒ “2.4 Cleaning injectors”, page 268
2.1 Assembly overview - fuel rail with injectors
rrectness of i
l purpos
1 - Fuel pressure sender -

G247-
nform
ercia

m
at
om
ion
⇒ page 280
c
in t
or
his
e
❑ Lubricate taper lightly

at
do
riv
with clean engine oil; do

p
cum
or
not lubricate thread

f
en
ng
t.
yi
❑ 22 Nm
Co
Cop py
ht. rig
2 - Fuel distributor rig ht
py by
co Vo
lksw
by
cted agen
Prote
⇒ page 264
AG.
3 - High-pressure pipe
❑ Do not alter shape.
⇒ page 294
❑ 25 Nm
4 - Bolt
⇒ page 264
❑ 8 Nm +90°
5 - Support ring
❑ Fuel rail exerts force
which secures injector
in cylinder head via this
support ring
❑ Clipped to -item 8-
6 - O-ring
❑ Lubricate with clean engine oil
7 - Spacer ring
8 - Injection valve
9 - Combustion chamber seal
❑ Do not treat with grease or other lubricant.
2. Injectors 263
Jetta 2015 ➤
2.2 Removing and installing fuel rail

Removing
AG. Volkswagen AG d
agen oes
lksw not
CAUTION d byV
o gu
ara
ise nte
r
The fuel system is pressurised.
ut
ho eo
ra
a
Danger of injury throughs fuel spray.
s c
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
– To release pressure, wrap a clean cloth around the connec‐
ility
ot
tion and carefully loosen the connection.
wit
, is n
h re
hole
spec
– Observe rules of cleanliness in repair instructions.
es, in part or in w
t to the co
– Remove high-pressure pipe ⇒ page 294 .
rrectness of i
l purpos
– Place a cloth underneath to catch any escaping fuel.

– Remove bolts -arrows- and pull fuel rail off injectors.
nform
ercia
Installing
m
a
com
tion in
r
te o
thi
s
– Renew O-ring.
iva
do
r
rp
cum
fo
– Apply mountings on fuel rail onto injectors.

en
ng
t.
yi Co
– Press fuel rail onto injectors as far as stop (first on right side, Cop py
ht. rig
then on left side). rig ht
py by
co Vo
by lksw
– Firmly press down fuel rail in area of bracket and screw in bolts Prote
cted AG.
agen
by two full turns.
– Install high-pressure pipe ⇒ page 294 .
Torque settings
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 263
2.3 Removing and installing injectors

♦ Tool set for FSI engines - T10133C- with -T10133/16- and -
T10133/19-

Jetta 2015 ➤
Removing
Note
Injectors must only be removed when the engine is cold.

– Removing fuel rail ⇒ page 264 .
– Remove O-ring -4- from injector -2-.
– Unplug electrical connector from corresponding injector.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
– Lever support ring -1- aoff
ut injector using a screwdriver -2-.
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit impact sleeve -T10133/18- over injector.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Injectors 265
Jetta 2015 ➤
– Carefully loosen injector with light blows onto impact sleeve.
Note
♦ Use a torque wrench to pull out the injector.

♦ Set the torque wrench to 5 Nm.
AG. Volkswagen AG d
agen oes
ksw
– Fit puller -T10133/19- to groove on injector. by
Vol not
gu
d ara
ise nte
– Fit removing tool -T10133/16 A- to puller. hor eo
aut ra
c
– Pull out injector by screwing in bolt -1-. ss
ce
e
nl
pt
du
– If the torque limit of »5 Nm« has been reached and the injector
an
itte
still can't be pulled out, withdraw the puller, and start anew.
y li
erm
ab
ility
ot p
– Use the impact sleeve to loosen the injector.
wit
, is n
– Repeat the procedure on each injector.
h re
hole
spec
es, in part or in w
t to the co
Note
♦ If the torque limit is exceeded, the injector may become dam‐
rrectness of i
aged.
l purpos
♦ Always renew the combustion chamber seal prior to reinstal‐

ling the injector.
nform
ercia
– Remove gasket for lower part of intake manifold.

m
at
om
ion
c
in t
Dismantling injector
or
his
ate
– Pull support ring -5- and spacer ring -3- off injector -2-.
do
priv
cum
for
– Carefully remove old combustion chamber seal -1-.

en
ng
t.
yi Co
op
– To do so, cut the ring open using a knife, or spread the ring
C py
t. rig
gh
using a small screwdriver, and pull it off towards front.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Take care not to damage the groove of injector. The injector must
be renewed if the groove is damaged.

Jetta 2015 ➤
Installing
– Clean hole in cylinder head using nylon brush -T10133/4- .
Note
♦ Renew combustion chamber seal and O-ring.

♦ Renew spacer ring if damaged.
– When reinstalling injector, remove any combustion residue

from groove for combustion chamber seal and from injector
shaft using a clean cloth.
– Fit assembly cone -T10133/5- with a new combustion cham‐

ber seal -1- on injector -2-.
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
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– Slide combustion chamber seal with assembly sleeve -
ility
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T10133/6- onto assembly cone -T10133/5- as far as it will go.
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– Turn assembly sleeve -T10133/6- around and push combus‐

n in
tion chamber ring seal into the respective groove.

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2. Injectors 267
Jetta 2015 ➤
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. It must be compressed again after sliding on and
this is done in two stages as described below.
– Push calibration sleeve -T10133/7- onto injector as far as stop

and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again, turning in opposite
direction.
– Push calibration sleeve -T10133/8- onto injector as far as stop

and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again, turning in opposite
direction.
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– Before installing injector -2- moisten new O-ring -4- with clean s
ce
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engine oil.
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Note
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The combustion chamber seal -1- must not be lubricated.
hole
spec
es, in part or in w
t to the co
– Fit gasket for lower part of intake manifold.
– Push injector by hand as far as it will go into cylinder head bore
(free of oil and grease). Ensure injectors are positioned cor‐ rrectness of i
rectly in cylinder head.
l purpos
Note
nform
ercia
♦ The injectors must insert easily. If necessary, wait until the

m
a
com
ti
combustion chamber ring seal has contracted sufficiently.

on in
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♦ Ensure injectors are correctly seated and positioned in cylin‐

s
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der head.
do
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• Electrical connector of injector must engage in respective re‐
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cess in cylinder head.
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– Installing fuel rail ⇒ page 264 . co Vo
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– Switch on ignition.
– Connect ⇒ Vehicle diagnostic tester and carry out guided
function Clear adaption values for injectors .
2.4 Cleaning injectors


Jetta 2015 ➤
♦ Ultrasonic cleaning device - VAS 6418-

♦ Mounting plate for injectors - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic parts catalogue (ETKA)
Note
♦ The ultrasonic unit must be filled with cleaning agent to upper

edge of holes (see detail).
♦ Observe ultrasonic unit safety regulations and operating in‐
structions.
Cleaning
– Remove injectors ⇒ page 264 .
– Insert injectors -1- all the way into mounting plate for injectors
- VAS 6418/1- -item 2-.
– Immerse injectors together with mounting plate for injectors -
VAS 6418/1- into cleaning fluid - VAS 6418/2- .
– Set rotary knob -4- to a temperature of 50°C.
– Set a cleaning time of 30 minutes with the rotating knob -5-.
n AG. Volkswagen AG
– Switch on ultrasonic
olks unit with button -3-.
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Note
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nl
The time set starts to elapse as soon as a cleaning temperature

pt
du
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of 50°C has been attained.

itte
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– After cleaning, renew combustion chamber ring seal for each

wit
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injector ⇒ page 264 .

h re
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spec
es, in part or in w
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2. Injectors 269
Jetta 2015 ➤
3 Air filter
⇒ “3.1 Assembly overview - air filter housing”, page 270
⇒ “3.2 Removing and installing air filter housing”, page 271
⇒ “3.3 Removing and installing resonator for intake air”,
page 272
3.1 Assembly overview - air filter housing
1 - Connection
⇒ “1.4 Removing and in‐
stalling connection for
turbocharger”,
page 248
2 - Spring-type clip
3 - Resonator for intake air
⇒ page 272
5 - Air filter upper part
❑ Remove dirt, leaves and
salt residues
6 - Air filter element AG. Volkswagen AG d
agen oes
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❑ Use only genuine air fil‐ ed by
V gu
ara
ter elements ⇒ Elec‐ horis nte
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tronic parts catalogue aut ra
c
(ETKA) . ss ce
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un
❑ For change intervals re‐

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fer to ⇒ Maintenance ta‐

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⇒ Maintenance ; Book‐
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let
spec
7 - Bump stop
t to the co
8 - Air filter lower part

❑ Remove dirt, leaves and
rrectne
salt residues
9 - Bolt
ss o
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❑ 3 Nm
f inform
mer
10 - Water drain hose

atio
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❑ Clean water drain hose.

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12 - Air duct
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❑ For upper part of air duct
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15 - Upper part of air duct
16 - Lower part of air duct
❑ On lock carrier.

Jetta 2015 ➤
3.2 Removing and installing air filter hous‐

ing
Removing
– Pull vacuum hose -2- off air filter housing.
– Release hose clips -3- and -4- and remove air duct -1-.
– Pull air filter housing -1- off ball head pins upwards.
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– First pull air filter housing off ball stud -C-. y li

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– Then, and only then, pull air filter housing off ball studs -B- and wit
, is n
-A-.
h re
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Installing
spec
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t to the co

• Keep to the sequence during assembly.
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Prote AG.
3. Air filter 271

Jetta 2015 ➤
– Press air filter housing -1- on ball studs -A- and -B-.
– Finally, press air filter housing on ball stud -C-.
Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the components and falsify the measured air
mass value. This would lead to loss of power, since a smaller
injection quantity is calculated.
♦ Always use Genuine part for air filter element.
♦ A clean air filter housing is essential.
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♦ Before fitting the air filter
olks
whousing,
age the ball pins on
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no intake
manifold must be moistened
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♦ Hose unions uand
tho air intake pipes and hoses must be free ofe or
oil and grease
ss
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before installation. ac
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♦ Use a silicone-free lubricant to install the air hoses.

un
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♦ Secure all hose connections with the hose clips corresponding
rm
ab
to original equipment ⇒ Electronic Parts Catalogue (ETKA) .
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♦ To prevent malfunctions, cover critical parts of the engine air
h re
intake (air pipes etc.) with a clean cloth when blowing out the
hole
spec
air filter housing with compressed air.
es, in part or in w
♦ Observe relevant disposal regulations. t to the co
– Remove salt residues, dirt and leaves from top and bottom part
rrectness of i
of air filter housing using a vacuum cleaner.

l purpos
– Blow out water drain with compressed air.

Torque settings
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3.3 Removing and installing resonator for

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Removing
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– Loosen hose clips -1- and -2-. opy
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– Remove resonator for intake air.
by
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Prote AG.
Installing
– Reinstall hose clips in their original positions.

Jetta 2015 ➤
4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 273
⇒ “4.2 Removing and installing intake manifold”, page 274
⇒ “4.3 Removing and installing throttle valve module GX3 ”, page
277
⇒ “4.4 Cleaning throttle valve module GX3 ”, page 278
4.1 Assembly overview - intake manifold
1 - Intake manifold
❑ Combined with charge
air cooler
⇒ page 274
2 - Coolant hoses
3 - Bolt
❑ Thread-cutting . Volkswagen AG
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❑ 7 Nm
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4 - Bracket
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5 - Ball pin
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❑ For engine cover panel

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6 - Bolt
spec
es, in part or in w

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tightening sequence
⇒ page 274
rrectness of i
7 - O-ring
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8 - Bolt
nform
ercia
❑ Thread-cutting
m
❑ Fit and screw in bolt by

a
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hand so that it screws

n in
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into old thread Then

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tighten bolt to torque.

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❑ 7 Nm
um
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9 - Intake manifold sender -
Co
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10 - Air intake pipe
AG.
11 - O-ring
❑ Before installing, moisten lightly with clean engine oil
12 - Throttle valve module - J338-
❑ Cleaning ⇒ page 278
❑ After throttle valve control module - J338- has been replaced, it must be re-adapted to engine control
unit - J623- . Use ⇒ Vehicle diagnostic tester for this.
4. Intake manifold 273

Jetta 2015 ➤
13 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to torque.
❑ 7 Nm
14 - Retaining clip
❑ For air intake pipe
15 - O-ring . Volkswagen AG
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❑ Renew aftera removal
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17 - Line for activated charcoal filter system
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18 - O-ring
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19 - Crankcase breather hose
spec
es, in part or in w
t to the co
Intake manifold - specified torque and tightening sequence
rrectness of i
– Tighten bolts in stages as follows:
l purpos

1 Bolts Starting in centre, screw in bolts alter‐
nform
ercia
-arrows- nately by hand until they make contact

m
at
2 Bolts Starting in centre, screw in bolts alter‐

om
ion
-arrows- nately to 8 Nm
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4.2 Removing and installing intake manifold
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Special tools and workshop equipment required Prote AG.

Jetta 2015 ➤
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♦ Assembly
ss tool - T10118-
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spec
t to the co
rrectness
♦ Release tools - T10527- and -T10527/1-
o
cial p
f inform
mer
atio
om
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Prote AG.
Removing
sulation .
CAUTION
Danger of injury through fuel spray.
Danger of functional impairment due to contamination/soiling

Jetta 2015 ➤
– First press hose connector -1- downwards, and then press re‐
lease tabs -arrows-.
– Keep release buttons pressed and pull off hose coupling.
– Press release tab on hose -2- for activated charcoal filter.
– Disconnect hose and move it clear.
– Release catch -arrow- and disconnect vacuum hose -1-.

– Move clear vacuum hose at air pipe -2-.
– Move clear air hoses at charge air pipe.
– Unscrew bolt -1-, and release clamps -arrows-.

– Pull off coolant hoses.
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pt
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ility
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1 - For activated charcoal filter system solenoid valve 1 - N80-

spec
es, in part or in w
t to the co
3 - For throttle valve module - GX3-

4 - For intake manifold sender - GX9- .
rrectness of i
– The -arrow- in the illustration can be disregarded.

l purpos
– Press release buttons and pull off hose -2- for activated char‐
coal filter.
nform
ercia
– Unclip fuel supply line -5- and coolant line -6- from intake
manifold and push them to one side.
m
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ion
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or
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ate
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rig ht
py by
co Vo
by lksw
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Prote AG.

Jetta 2015 ➤
– Disconnect connector -1- from fuel pressure sender - G247- .

– Also disconnect connector from oil pressure switch.
– Loosen hose clips -2- and pull off coolant hoses.

– Remove intake manifold -1-.
Installing
• Renew seals and O-rings. AG. Volkswagen AG d
agen oes
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– Install air filter housing ⇒ page 271 . d by V gu
ara
rise nte
– Add coolant ⇒ page 197 . utho eo
ra
s a c
– Install noise insulation ⇒ General body repairs, exterior; Rep. s
ce
le

un
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d
tion .
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Torque settings
ility
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spec
4.3 Removing and installing throttle valve
t to the co
module - GX3-
Throttle valve module - GX3- consists of
rrectne
♦ Throttle valve module - J338-
ss
♦ Throttle valve drive for electronic power control - G186-
o
cial p
♦ Throttle valve drive angle sender 1 for electronic power control f inform
mer
- G187-
atio
om
♦ Throttle valve drive angle sender 2 for electronic power control

c
i
or
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- G188-
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p
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fo
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♦ Release tools - T10527- and -T10527/1-

t.
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Cop py
t. rig
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by
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Prote AG.

Jetta 2015 ➤
Removing
– Unscrew bolts -arrows- and remove throttle valve module -
GX3- -1- with adapter -2-. wage
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Vol t gu
Installing d by ara
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Install in the reverse order of removal, observingauththe following: eo
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– After throttle valve control module - GX3- has been replaced,
ce
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nl
pt
it must be re-adapted to engine control unit - J623- . Use
du
an
⇒ Vehicle diagnostic tester for this. itte
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ab
ility
Torque settings
ot p
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hole
spec
es, in part or in w
4.4 Cleaning throttle valve module - GX3-
t to the co
Note
rrectness of i
l purpos
♦ If a new engine control unit - J623- is installed, the throttle

valve module must be adjusted.
nf
ercia
♦ Contamination and coking in end stop can result in incorrect
orm
adaptation values.
m
atio
om
n in
♦ When cleaning the throttle valve housing, take care not to
or c
thi
scratch it.
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♦ Acetone (commercially available) Cop py
t. rig
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♦ Brush p by
co Vo
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Procedure Prote AG.
– Remove throttle valve module - GX3- ⇒ page 277 .

– Open throttle valve by hand and lock it in open position with a
wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.

Jetta 2015 ➤
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe the inside of the throttle valve housing with a lint-free
cloth.
– Allow acetone to dry off completely.
– Install throttle valve module - GX3- ⇒ page 277 .
– Delete learnt values, and adapt engine control unit - J623- to
throttle valve module - J338- . Use ⇒ Vehicle diagnostic tester
for this.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
h
aut ra
ss c
ce
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un
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ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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tion in
r
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by c lksw
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Prote AG.

Jetta 2015 ➤
5 Senders and sensors

⇒ “5.1 Removing and installing fuel pressure sender G247 ”, page
280
⇒ “5.2 Checking fuel pressure sender G247 ”, page 281
⇒ “5.3 Removing and installing intake manifold sender GX9 ”,
page 283
5.1 Removing and installing fuel pressure

sender - G247-
lkswage es n
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tho
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a ac
ss
ce
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nl
pt
du
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itte
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ab
ility
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♦ Socket 27 mm - T40218- or commercially available 27 mm wit

, is n
hexagon socket insert

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2015 ➤
Removing
– Unclip fuel supply line -1- from intake manifold, and push it to
one side.
CAUTION
– Unscrew fuel pressure sender - G247- -2- using socket 27 mm

- T40218- .
Installing
AG. Volkswagen AG d
agen
Note Volksw
oes
not
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d ara
ise nte
Do not lubricate threaduthor
of fuel pressure sender. eo
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Torque settings
e
nl
pt
du
an
itte

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erm
ab
ility
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5.2 Checking fuel pressure sender - G247-

wit
, is n
h re
hole

spec
es, in part or in w
♦ ⇒ Vehicle diagnostic tester

t to the co
♦ Test instrument adapter/DSO (3-pin) - VAS 5570-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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♦ Pressure sensor tester - VAS 6394-
ht
pyri by
Vo
co lksw
by
♦ Socket 27 mm long, commercially available
cted agen
Prote AG.
5. Senders and sensors 281

Jetta 2015 ➤
Procedure
CAUTION
– Remove fuel pressure sender - G247- ⇒ page 280 .

– Lubricate taper seal of adapter -VAS 6394/3- with clean en‐
gine oil and screw into fuel rail (22 Nm).
AG. Volkswagen AG d
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ed
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aut ra
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nl
pt
du
an
itte
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ab
ility
ot p
– Unscrew plug -2- and screw fuel pressure sender - G247- into
wit
, is n
tester -VAS 6394/1- .

h re
hole
spec
– Connect pressure line -1- of tester to adapter - VAS 6394/3- .

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
– Connect vehicle and fuel pressure sender - G247- electrically

or
thi
using test instrument adapter/DSO (3-pin) - VAS 5570- .

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rig ht
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by lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Switch on tester -VAS 6394/1- by pressing button -A- once

briefly.
Note
♦ When button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If tester -VAS 6394/1- does not indicate 0 bar, zero the tester
⇒ Operating instructions .

– Start engine and run at idling speed.
– In self-diagnosis, select Engine electronics olks.wagen AG
en AG. V g does
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– Then, select Measured values
by .
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ara
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– Select Fuel pressureuthofrom
r
the list. eo
ra
sa c
– Compare pressure displayed
s
on tester -VAS 6394/1- with ac‐
ce
e
nl
tual value displayed on ⇒ Vehicle diagnostic tester.
pt
du
an
itte
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– Watch fuel pressure on ⇒ Vehicle diagnostic tester.
erm
ab
ility
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• A maximum pressure deviation of 5 bar is permissible.
wit
, is n
h re
– If the deviation is greater than 5 bar, renew fuel pressure
hole
spec
sender - G247- .
es, in part or in w
t to the co
– Repeat test with new fuel pressure sender - G247- and com‐
pare both measured values.
– If measured values are now the same, install new fuel pres‐
rrectness of i
sure sender - G247- .
l purpos
– If measured values are not the same again, check electrical

connection between fuel pressure sender - G247- and engine
nform
ercia
control unit - J623- ⇒ Current flow diagrams, Electrical fault

finding and Fitting locations.
m
at
om
io
Torque settings
n
c
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at
do
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or
5.3 Removing and installing intake manifold

f
en
ng
t.
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op
sender - GX9- C py
t. rig
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pyri by
Intake manifold sender - GX9- consists of:
co Vo
by lksw
cted agen
Prote AG.
♦ Intake air temperature sender 2 - G299-
♦ Intake manifold pressure sender - G71-
Removing
5. Senders and sensors 283

Jetta 2015 ➤

– Release fasteners, and remove intake manifold sender -
GX9- .
Installing
• Renew O-ring.
Note AG. Volkswagen AG d

agen oes
olksw not
V
If the retaining tabs brokeed by off during removal, the sender gcan ua be
ran
mounted using two thosecuring
ris bolts ⇒ Electronic Parts Catalogue tee.
or
au ac
ss
ce
e
nl
pt
du
an
Torque settings
itte
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erm
ab
ility
ot p
wit
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Intake manifold sender - GX9- 3 Nm
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
6 Engine control unit

⇒ “6.1 Removing and installing engine (motor) control unit J623
”, page 285
6.1 Removing and installing engine (motor)

control unit - J623-
⇒ “6.1.1 Removing and installing engine control unit J623 without
protective housing”, page 285
⇒ “6.1.2 Removing and installing engine (motor) control unit J623
with protective housing”, page 286
6.1.1 Removing and installing engine control

unit - J623- without protective housing
Note
. Volkswagen AG
gen AG does
swa
If the engine control y V unit is to be renewed, connect
olk not ⇒ Vehicle di‐
gu
agnostic tester,
risedand perform function 01 - Renew engine
b ara
nte con-
trol unitut.h o eo
ra
a c
ss
ce
e
Removing
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove cover for E-box in engine compartment -arrows-.

wit
, is n
h re
– Release connector from engine control unit and pull it off.

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
– Carefully press locking tabs outwards on side guides -3- using

or c
a screwdriver -2-.
thi
te
sd
iva
o
r
– Pull engine control unit -1- upwards out of side guides -3-.
rp
cu
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Engine control unit 285

Jetta 2015 ➤
Installing
– Slide engine control unit -1- into side guides -3- until it engag‐
es.
– Connect connector to engine control unit and lock it.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Install cover for E-box -arrows-. s
ce
le
un
pt
an
d
itte
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rm
ab
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
pe
ility
moving and installing battery .
ot
wit
, is n
h re
After having installed a new engine control unit, the following work
hole
spec
must be carried out
es, in part or in w
t to the co
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
rrectness of i
– Switch on ignition, and select following menu options on⇒ Ve‐
l purpos
hicle diagnostic tester:

♦ 01 - Engine electronics
nform
ercia
♦ Guided Functions
m
a
com
tion in
♦ 01 - Renew engine control unit
r
te o
thi
s
iva
do
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6.1.2 Removing and installing engine (motor)

rp
cum
fo
en
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control unit - J623- with protective hous‐

n
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op py
ing
t. C rig
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pyri by
Vo
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by c lksw
Special tools and workshop equipment required Prote
cted AG.
agen
♦ Angle grinder e.g. axial grinder - VAS 6682-
Note
♦ If the engine control unit is to be renewed, connect ⇒ Vehicle

diagnostic tester, and perform function 01 - Renew engine
control unit .
♦ The protective housing is secured with shear-head bolts. The

shear-head bolts cannot be removed without being damaged.
Use e.g. the axial grinder - VAS 6682- or a commercially avail‐
able angle grinder to remove the shear-head bolts. If the
protective housing is damaged, it must be renewed.
Removing
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .

Jetta 2015 ➤
– Remove cover for E-box in engine compartment -arrows-.
– Make wiring harness accessible and pull off engine control unit
upwards from the bracket. To do this, press catches -arrows-
to side.
. Volkswagen AG
gen AG does
– Remove bolts -A-. To do this, push wiring harness to Vside
olks as
wa not
far as possible. Remove retainer -B-. ed
by gu
ara
is nte
or eo
– Release connector and pull it off engine control
au unit.
th ra
ss 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
Installing
rrectne
– Slide engine control unit -1- into side guides -3- until it engag‐
es.
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.
6. Engine control unit 287

Jetta 2015 ➤
– If the engine control unit has been renewed, secure arm -4- to
engine control unit using shear-head bolts -6-.
– Tighten shear bolts -6- until bolt heads shear off.
– Reconnect connectors -1- and -3- to engine control unit and
lock them in position.
– Secure locking device -5- using shear-head screws -2-. n AG. Volkswagen AG do
swage es n
– Tighten shear bolts -2- until bolt heads shear off. by Vo lk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
an
itte
y li
– Install cover for E-box -arrows-.
erm
ab
ility
ot p
wit
, is n
h re
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
hole
moving and installing battery .
spec
es, in part or in w
t to the co
After having installed a new engine control unit, the following work
must be carried out
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
rrectness of i
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
riv
♦ 01 - Renew engine control unit

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

Jetta 2015 ➤
7 High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 289
⇒ “7.2 Removing and installing high-pressure pump”, page 292
⇒ “7.3 Removing and installing high-pressure pipe”, page 294
7.1 Assembly overview - high-pressure

pump
⇒ “7.1.1 Assembly overview - high-pressure pump, Hitachi”, page
289
⇒ “7.1.2 Assembly overview - high-pressure pump, Continental”,
page 290
⇒ “7.1.3 Assembly overview - high-pressure pump, Bosch”, page
291
7.1.1 Assembly overview - high-pressure pump, Hitachi
1 - Roller tappet
❑ When installing nlubri‐
AG. Volkswagen AG d
wage oes
cate lightly
o with clean
l ks not
yV gu
engine
se
d b oil ara
n
ri tee
ho
2 - O-ring
au
t or
ac
ss
ce
le
un
pt
❑ When installing lubri‐

an
d
itte
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cate lightly with clean

erm
ab
engine oil
ility
ot p
wit
is n
3 - High-pressure pump
h re
ole,
❑ With fuel pressure regu‐

spec

t to the co
❑ Do not dismantle.
⇒ page 292
rrectne
ss

o
cial p
f i

nform
⇒ page 294
mer
atio

om
n
c
❑ Lubricate thread of un‐

or
n thi
e
ion nuts with clean en‐

t
sd
va
gine oil
i
o
pr
cum
r
fo
❑ 16 Nm +45°
en
ng
t.
yi Co
op
5 - Bolt
C py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted
agen
Prote AG.
tightening sequence
⇒ page 290
6 - Hose clamp
7 - Fuel supply line
8 - Electrical connector
7. High-pressure pump 289

Jetta 2015 ➤
High-pressure pump - specified torque and tightening sequence

To prevent flange of high-pressure pump from being deformed
during installation, install high-pressure pump as follows:
1 Bolts -3- Screw in by hand as far as stop
2 Bolts -3- Tighten one turn alternately until
flange of high-pressure pump makes
contact with camshaft housing
3 Bolts -3- 20 Nm
4 Bolts -3- Turn 90° further
7.1.2 Assembly overview - high-pressure pump, Continental
1 - Roller tappet
engine oil
2 - O-ring
engine oil
❑ With fuel pressure regu‐
❑ Removing and installing AG. Volkswagen AG d
agen oes
ksw
⇒ page 292 by
Vol not
gu
ara
ed
is nte
4 - High-pressure pipe hor eo
aut ra
❑ Renew after removal ss c
ce
e

nl
pt
du
an
⇒ page 294
itte
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erm
ab

ility
ot p

wit
, is n

h re
hole
gine oil
spec
es, in part or in w
❑ 16 Nm +45°
t to the co
5 - Bolt
rrectness of i

l purpos
tightening sequence
⇒ page 291
nf
ercia
6 - Hose clamp
orm
m
7 - Fuel supply line

atio
om
n in
c
or
thi
te
sd
iva
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Jetta 2015 ➤
u
4-cylinder
ss
a
injection engine (1.4 l, 4V, EA211, turbocharger) ac
- Edition 07.2019
ce
le
un
pt
an
d
itte
y li
erm
ab
Install high-pressure pump as follows to avoid deformation of the
ility
ot p
high-pressure pump flange:
wit
is n
h re
ole,
spec
t to the co
1 Bolts -3- Screw in by hand as far as stop
2 Bolts -3- Tighten one turn alternately until
rrectne
s
3 Bolts -3- 20 Nm
s o
cial p
f i
4 Bolts -3- Turn 90° further
nform
mer
atio
m
7.1.3 Assembly overview - high-pressure pump, Bosch

o
n
c
i
or
n thi
te
sd
iva
o
r
1 - Bolt
p
cum
r
fo
en
ng

t.
yi Co
tightening sequence Cop py
. rig
⇒ page 292
t
gh ht
pyri by
Vo
co
by lksw
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Prote AG.
❑ With fuel metering valve
- N290- .
⇒ page 292
3 - O-ring
engine oil
4 - Roller tappet
engine oil
5 - Fuel return line
⇒ page 294
❑ Unions must be free of
damage
gine oil
❑ 16 Nm +45°

Jetta 2015 ➤

To prevent flange of high-pressure pump from being deformed
during installation, fit high-pressure pump as follows:
en AG. V
olkswagen AG
wag does
– Tighten bolts in stages as follows: olks not
byV gu
ara
ed nte
ris
Stage Component Specified thotorque/turning further angle eo
au ra
c
ss
1 Bolts -arrows- Screw in by hand as far as stop
ce
le
un
pt
2 Bolts -arrows- Tighten one turn alternately until
an
d
itte
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rm
ab
pe
ility
ot
wit
3 Bolts -arrows- M 6: 8 Nm
, is n
h re
M 8: 20 Nm
hole
spec
4 Bolts -arrows- Turn 90° further
es, in part or in w
t to the co
7.2 Removing and installing high-pressure
pump
rrectness of i
l purpos
Note
nform
ercia
Procedure applies to all three versions.

m
a
com
tion in
r

te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Ratchet attachment - V.A.G 1410/3-

Jetta 2015 ➤
♦ Bit XZN 10 - T10385-
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
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Removing
h re
hole
spec
• Engine cold.
es, in part or in w
t to the co
CAUTION
rrectness of i
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
e
Risk of malfunction due to soiling ⇒ page 1 .

at
do
priv
c
– Remove high-pressure pipe ⇒ page 294 .
um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh
– Place a cloth underneath to catch any escaping fuel.
ht
pyri by
Vo
co lksw
by
cted
– Release hose clip -2- and detach fuel supply hose.
agen
Prote AG.
– Unscrew bolts -3- and detach high-pressure pump with roller

tappet.

Jetta 2015 ➤
Installing agen
AG. Volkswagen AG d
oes
olksw not
– Check roller tappet for damage and renew ifednecessary.
by V gu
ara
ris nte
– Moisten roller tappet -1- with clean engine
aut oil.
ho eo
ra
ss c
– Insert oiled roller tappet -1- into camshaft housing.
ce
e
nl
pt
du
an
– When doing this, lug on plunger must locate in guide of high-
itte
y li
pressure pump.
erm
ab
ility
– Turn crankshaft in direction of engine rotation until roller tappet ot p
wit
, is n
is at bottom dead centre.
h re
hole
spec
• Renew O-ring.
es, in part or in w
t to the co
– Insert new, lubricated O-ring -2- in groove of high-pressure
pump -3-.
– Tighten bolts ⇒ page 294 .
rrectness of i
– Check fuel system for leaks.
l purpos
Torque settings
nform
ercia
♦ ⇒ “7.1 Assembly overview - high-pressure pump”, page 289

m
at
om
ion
7.3 Removing and installing high-pressure
c
in t
or
his
e
pipe
at
do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Torque wrench - V.A.G 1331- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Tool set - T10395 A-
Removing
– Remove throttle valve module - GX3- ⇒ page 277 .

Jetta 2015 ➤
CAUTION
• Place a cloth underneath to catch any escaping fuel.

– Unscrew union nuts -arrows- and detach high-pressure pipe.
Installing
– Lubricate thread of union nuts with clean engine oil.
– Hand-tighten union nuts for high-pressure pipe (make sure
that pipe is not under stress).
Note
Use an open-end wrench to counterhold at the hexagon on the

high-pressure pump when tightening to the final specified torque.
. Volkswagen AG
gen AG does
– Tighten union nuts using torque wrench V- oV.A.G
lksw
a
1331- and not
insert - T10395 A- . ed
by gu
ara
is nte
or eo
– Install throttle valve module - GX3-
au ⇒ page
th 277 . ra
ss c
Torque settings
ce
e
nl
pt
du
an
♦ ⇒ “7.1 Assembly overview - high-pressure pump”, page 289
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2015 ➤
8 Lambda probe
⇒ “8.1 Assembly overview - Lambda probe”, page 296
⇒ “8.2 Removing and installing Lambda probe”, page 298
8.1 Assembly overview - Lambda probe

⇒ “8.1.1 Assembly overview - lambda probe, engine codes CZCA,
CZDA”, page 296
⇒ “8.1.2 Assembly overview -lambda probe, engine code CZTA”,
page 297
8.1.1 Assembly overview agen

-AGlambda
. Volkswageprobe,
n AG d
oes
en‐
gine codesd bCZCA,
yV
olksw
CZDA not
gu
ar
e an
ris tee
tho or
au ac
Note ss
ce
le
un
pt
an
d
♦ New lambda probes are coated with an assembly paste. This

itte
y li
paste must not get into the slots on the Lambda probe body.
rm
ab
pe
ility
ot
♦ In the case of a used Lambda probe, grease only the thread
wit
, is n
with high-temperature paste. This paste must not get into the
h re
hole
slots on the Lambda probe body. High-temperature paste ⇒
spec
Electronic parts catalogue (ETKA)
es, in part or in w
t to the co
♦ During installation, the electrical connecting cable of the
Lambda probe must be secured at the same points. The wire
must be prevented from touching the exhaust pipe.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
1 - Lambda probe 1 after cata‐

lytic converter - GX7-
❑ Consisting of:

Z29-
⇒ page 298
❑ 55 Nm
❑ For Lambda probe 1 af‐
ter catalytic converter -
GX7- .
❑ For Lambda probe 1 be‐
fore catalytic converter -
GX10- .
❑ Consisting of:
Lambda probe - G39- lkswage es n
o ot g
byV ua
d ran
Lambda probe heater - ir se tee
tho
or
Z19- au ac
ss
ce
e

nl
pt
du
⇒ page 298
an
itte
y li
erm
❑ 55 Nm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
8.1.2 Assembly overview -lambda probe, en‐ t to the co

gine code CZTA
rrectness of i
l purpos
Note
nf
ercia

rm
m
atio
om
n in
c

or
thi
te
sd
iva

o
r
rp
cu

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m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
must be prevented from touching the exhaust pipe. p by
co Vo
by lksw
cted agen
Prote AG.
8. Lambda probe 297

Jetta 2015 ➤

❑ Consisting of:
Lambda probe - G39-
Lambda probe heater -

Z19-
⇒ page 298
❑ 55 Nm
❑ For Lambda probe 1 be‐
fore catalytic converter - n AG. Volkswagen AG do
GX10- . lkswage es n
o ot g
byV ua
d
3 - Lambda probe 1 after cata‐ o
ir se
ran
tee
lytic converter - GX7- auth or
ac
ss
❑ Consisting of:
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Z29-
spec
es, in part or in w
t to the co
⇒ page 298
❑ 55 Nm
rrectness of i
l purpos
❑ For Lambda probe 1 af‐

ter catalytic converter -
GX7- .
nform
ercia
5 - Bracket
m
a
com
tio
❑ For connector for Lamb‐
n in
r
da probe 1 after catalytic

te o
thi
converter - GX7-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
8.2 Removing and installing Lambda probe
C py
t. rig
gh ht
pyri by
Vo
⇒ “8.2.1 Removing and installing Lambda probe 1 before catalytic
co lksw
by
cted agen
converter GX10 ”, page 298 Prote AG.
⇒ “8.2.2 Removing and installing Lambda probe 1 after catalytic

converter GX7 ”, page 300
8.2.1 Removing and installing Lambda probe

1 before catalytic converter - GX10-
Lambda probe 1 before catalytic converter - GX10- consists of
♦ Lambda probe - G39-
♦ Lambda probe heater - Z19-

Jetta 2015 ➤
♦ Lambda probe open ring spanner set - 3337-en AG. Volkswagen AG

wag does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Disconnect connector -2- for Lambda probe 1 before catalytic
converter - GX10- .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Lambda probe 299

Jetta 2015 ➤
– Unscrew Lambda probe 1 before catalytic converter - GX10-

-2- using tool from Lambda probe open ring spanner set -
3337- .
Installing
Note

Electronic parts catalogue (ETKA)agen AG. Volkswagen AG do
w es n
olks ot g
♦ During installation, the electrical
ed
by
V
connecting cable of the ua
ra
Lambda probe must be ho
rissecured at the same points. The wire ntee
must be preventeds afrom
ut touching the exhaust pipe. or
ac
s
ce
le
un
pt
Vehicles as of July 2015
an
d
itte
y li
– If a lambda probe has been renewed, erase learnt values and
rm
ab
pe
ility
adapt lambda probe to engine control unit ⇒ Vehicle diagnostic
ot
tester.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Guided Functions rrectness of i
♦ 01 - Lambda probe adaption

l purpos

nform
ercia
Torque settings
m
♦ ⇒ “8.1 Assembly overview - Lambda probe”, page 296

com
tion in
r
te o
thi
8.2.2 Removing and installing Lambda probe

s
iva
do
r
1 after catalytic converter - GX7-

rp
cum
fo
en
ng
t.
yi
Lambda probe 1 after catalytic converter - GX7- consists of
Co
Cop py
t. rig
gh ht
♦ Lambda probe after catalytic converter - G130- yri
p by
o Vo
by c lksw
cted
♦ Lambda probe 1 heater after catalytic converter - Z29-
agen
Prote AG.

♦ Lambda probe open ring spanner set - 3337-

Jetta 2015 ➤
Removing
Vehicles with engine codes CZDA, CZCA
– Disconnect connector -1- for Lambda probe 1 after catalytic
converter - GX7- .
G. Volkswagen AG d
– Unscrew lambda probe 1 after catalytic converter - GX7- lk-1- wage
nA oes
o s not
using a suitable tool from lambda probe open ring spanner
db
y V set gu
ara
- 3337- . or
ise nte
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Vehicles with engine code CZTA
rrectness of i
– Unscrew nuts -arrows- for underbody cladding (right-side) and
pull underbody cladding downwards slightly.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Lambda probe 301

Jetta 2015 ➤
– Unclip connector -arrow- from retainer -2- and disconnect it.

– Unscrew lambda probe 1 after catalytic converter - GX7- -1-
using a suitable tool from lambda probe open ring spanner set
- 3337- .
Installing
Note
♦ New lambda probes are coated

wage
with
n AG. Volkswaan
genassembly
AG do
e
paste. This
paste must not get
y V into the slots on the Lambda probe
olks s no
t gu body.
b ara
ed
♦ In the casethof
or a used Lambda probe, grease only the thread
is nte
e
with high-temperature
sa
u paste. This paste must not get intoothe
ra
c
s
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
must be prevented from touching the exhaust pipe.
wit
, is n
h re
hole
Vehicles as of July 2015

spec
es, in part or in w
– If a lambda probe has been renewed, erase learnt values and t to the co
adapt lambda probe to engine control unit ⇒ Vehicle diagnostic
tester.
rrectness of i

l purpos
nf
ercia
rm
m
atio
m
♦ 01 - Lambda probe adaption

o
n in
or c
thi

te
sd
iva
o
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rp
cu
Torque settings
o
m
f
en
ng
t.
♦ ⇒ “8.1 Assembly overview - Lambda probe”, page 296
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
AG. Volkswagen AG d
26 – Exhaust system d by Volksw
agen oes
not
gu
ara
rise nte
ho eo
1 Exhaust pipes and silencers ut ra
s a c
s
ce
e
nl
⇒ “1.1 Assembly overview - silencers”, page 303
pt
du
an
itte
y li
⇒ “1.2 Separating exhaust pipes from silencers”, page 304
erm
ab
ility
ot p
⇒ “1.3 Removing and installing rear silencer”, page 305
wit
, is n
h re
⇒ “1.4 Aligning exhaust system free of stress”, page 306
hole
spec
⇒ “1.5 Checking exhaust system for leaks”, page 306
es, in part or in w
t to the co
⇒ “1.6 Installation position of clamp”, page 307
1.1 Assembly overview - silencers
rrectness of i
l purpos
1 - Exhaust pipe with rear si‐

lencer
nf
ercia
o
rm
m
atio
⇒ page 305
om
n in
c
❑ Observe installation po‐

or
thi
sition
te
sd
iva
o
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rp
cu
2 - Bolt
o
m
f
en
ng

t.
yi Co
op py
❑ 25 Nm t. C rig
gh ht
pyri by
3 - Repair clamp-type clip
co Vo
by lksw
cted agen
Prote
❑ Marked by indentation
AG.
on exhaust pipe.
⇒ page 307
4 - Securing strap
❑ Fuel tank to body
5 - Bolt
❑ Securing rear tension‐
ing strap to vehicle
body.
6 - Bolt
❑ Front of securing strap
to vehicle body
❑ Securing centre silencer
bracket to vehicle body.
7 - Rear tunnel cross-piece
⇒ General body repairs,
exterior; Rep. gr. 66 ;
Underbody cover; Re‐
moving and installing
tunnel cross-piece .
8 - Nut
❑ Rear tunnel cross-piece
❑ 20 Nm
1. Exhaust pipes and silencers 303

Jetta 2015 ➤
1.2 Separating exhaust pipes from silencers

♦ A separating point has been engineered in the connecting pipe
should the centre silencer and rear silencer need to be re‐
placed separately.
♦ The cutting point is marked by indentations on the periphery
of the exhaust pipe.
♦ Body repair saw - V.A.G 1523 B- or
♦ Chain-type pipe cutter - VAS 6254-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
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
♦ Safety goggles
Disconnecting
rrectness of i
CAUTION
l purpos
Danger of severe burns from hot exhaust system.

nform
Risk of burns to hands and other parts of body.

ercia
– Allow exhaust system to cool.

m
at
om
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
To avoid injury from metal shavings, wear eye protection and op
yi Co
protective clothing.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Remove underbody cladding ⇒ General body repairs, exteri‐ Prote
cted AG.
agen
or; Rep. gr. 66 ; Underbody cladding; Removing and installing
underbody cladding .
304 Rep. gr.26 - Exhaust system

Jetta 2015 ➤
– Cut through exhaust pipe at cutting point -arrow 2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
Connecting
swage es n
Note byV
olk ot g
ua
d ran
ir se tee
o
A second amechanic
uth
is required to bolt on the repair clamp-type or
ac
clip. ss
ce
e
nl
pt
du
an
– Fit front silencer to retainers. Front clamp remains loose on
itte
y li
erm
pipes.
ab
ility
ot p
– Align rear silencer horizontally and hold it in that position.
wit
, is n
h re
hole
spec
– Position repair clamp so that it is flush with the markings
es, in part or in w
-arrow 1- and -arrow 3-.
t to the co
– Turn repair clamp -4- as shown in illustration, and tighten it.
– Then, align exhaust system free of tension ⇒ page 306 .
rrectness of i
– Install underbody cladding ⇒ General body repairs, exterior;
l purpos
Rep. gr. 66 ; Underbody cladding; Removing and installing

nf
ercia
o
Torque settings
rm
m
atio
m
♦ ⇒ “1.1 Assembly overview - silencers”, page 303

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
1.3 Removing and installing rear silencer

o
m
f
en
ng
t.
yi Co
Removing t. Cop py
rig
gh ht
pyri by
CAUTION
co Vo
by lksw
cted agen
Prote AG.
Danger of severe burns from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool.
– Remove underbody cladding ⇒ General body repairs, exteri‐

or; Rep. gr. 66 ; Underbody cladding; Removing and installing
– If necessary, separate exhaust pipes/silencers ⇒ page 304 .
– Loosen rear silencer bolts and remove exhaust system.
Installing
Note
A 2nd mechanic is required to tighten the rear clamp (repair

clamp).
– Fit front silencer to retainers. Front clamp remains loose on

pipes.
– Align rear silencer horizontally and hold it in that position.
– Position rear clamp at two outer markings, and tighten it
⇒ page 305 .
– Then, align exhaust system free of tension ⇒ page 306 .

Jetta 2015 ➤
– Install underbody cladding ⇒ General body repairs, exterior;

Rep. gr. 66 ; Underbody cladding; Removing and installing
Torque settings
1.4 Aligning exhaust system free of stress

Procedure
• The exhaust system must be aligned when cold.
Note
-Arrow- points in direction of travel.
– Loosen bolt connections for front clamp -arrow-.
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
– Push exhaust system towards front of vehicle until preloading

h re
ole,
at mounting for exhaust pipe -a- = 5 mm.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Align end exhaust pipes

t
sd
iva
o
pr
cum
– Align rear silencer so that there is an equal distance -a- and

r
fo
en
ng
-b- between bumper cut-out and tailpipes.

t.
yi Co
Cop py
– Unfasten rear silencer mounting to align tailpipes.
t. rig
gh ht
pyri by
Vo
o
– Install clamp ⇒ page 307 .
c by lksw
cted agen
Prote AG.
Torque settings
1.5 Checking exhaust system for leaks

Procedure
– Start engine and run it at idling speed.

AG. Volkswagen AG d
agen oes
o lksw not
yV gu
ed b Jetta
ara
nte
2015 ➤
ris
tho (1.4 l, 4V, EA211, turbocharger) - Edition e07.2019
or
au ac
ss
– Seal end exhaust pipes with cloths or plugs, for example, for
ce
le
un
pt
the duration of the leakage test.
an
d
itte
y li
erm
ab
– Check (by listening) points of connection between exhaust
ility
ot p
manifold and the cylinder head, between turbocharger and
wit
front exhaust pipe etc. to make sure there are no leaks.
is n
h re
ole,
– Repair any leaks found.
spec
t to the co
1.6 Installation position of clamp
Installation position of front clamp
rrectne
• Installation dimension -a- is approx. 1 cm.
s
A - End of bead
s o
cial p
f
1 - Clamping sleeve
inform
mer
2 - Front exhaust pipe
atio
om
n
a - Installation dimension
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Installation position of repair clamp, rear

t.
yi Co
Cop py
– Cut through exhaust pipe at separating point -arrow 2-. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– When installing, position repair clamp -4- at side markings (ar‐

rows -1- and -3-).
– Install repair clamp so that bolt ends do not protrude beyond
lower edge of double clamp -arrow-.

Jetta 2015 ➤
Specified torque and installation dimensions of clamping sleeve

Two-piece clamp -A- 25 Nm
Clamp -B- with continuous clip. 35 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
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
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 309
⇒ “2.2 Removing and installing catalytic converter”, page 310
2.1 Assembly overview - emission control
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Nut
tightening sequence
⇒ page 310
4 - Bolt
❑ 20 Nm
5 - Nut
tightening sequence
⇒ page 310
6 - Bracket
7 - Bracket AG. Volkswagen AG d
agen oes
lksw not
8 - Bolt d by V o gu
ara
se nte
❑ Specified
thori torque and eo
tightening
s au sequence ra
c
s
⇒ page 310
ce
le
un
pt
9 - Bolt
an
d
itte
y li
erm

ab
ility
tightening sequence
ot p
wit
⇒ page 310
is n
h re
ole,
10 - Front exhaust pipe with

spec
catalytic converter
t to the co
❑ Do not bend flexible joint

more than 10°. Other‐
wise, it can be dam‐
rrectne
aged.
❑ Install flexible joint so
ss
that it is not under tension

o
cial p
f i
❑ Take care not to damage wire mesh on decoupling element.

nform
mer
❑ Protect catalytic converter from damage by knocks and impact

atio
m

o
n
c
i
or
❑ Do not remove protective packaging from replacement part until you are ready to fit the flexible joint
thi
te
sd
va
❑ Aligning exhaust system free of tension ⇒ page 306 .

i
o
pr
cum
r
fo
11 - Screw-type clamp
en
ng
t.
yi Co
op
❑ Renew after removal C py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
12 - Seal Prote AG.

2. Emission control 309

Jetta 2015 ➤
13 - Turbocharger
14 - Nut
❑ 30 Nm
15 - Front clamp
AG. Volkswagen AG d
❑ Align exhaust system free lof kswtension before tightening
agen oes ⇒ page 306 .
not
o
❑ Fitting position ⇒ page yV
b307 gu
ara
ed
ris nte
❑ Tighten threadedut connections evenly.
ho eo
r a ac
ss
ce
e
nl
pt
du
an
Installing catalytic converter - specified torque and sequence
itte
y li
erm
ab
ility
1 – Fit catalytic converter to tur‐
ot p
bocharger and fit screw-type
wit
, is n
h re
clip -arrow- without tightening
hole
spec
2 – Loosely screw in bolts -3, 5- • It should still be
es, in part or in w
and bolts -1, 2, 4- by hand possible to move
t to the co
catalytic converter
and bracket.
rrectness of i
3 – Tighten screw-type clip 15 Nm
l purpos
-arrow-
4 – Tighten bolts and nuts in the 20 Nm
sequence -1 … 5-
nform
mercia
at
om
i
2.2 Removing and installing catalytic con‐
on
c
in t
or
verter
his
ate
do
priv
cum
or
CAUTION
f
en
ng
t.
yi Co
op
Danger of severe burns from hot exhaust system. C py
t. rig
gh ht
Risk of burns to hands and other parts of body. pyri by
Vo
o
by c lksw
– Allow exhaust system to cool. cted agen
Prote AG.

♦ High-temperature paste ⇒ Electronic parts catalogue (ETKA) .
Note
The catalytic converter is removed together with the front exhaust

pipe.
Removing
– Reinstall all cable ties in the same locations when installing.
– Remove electrical connectors -1- and -2- from retainer and
disconnect. Move electrical lines free.

Jetta 2015 ➤
– Unscrew bolts -arrows- on camshaft housing.
Note
♦ Do not loosen bolts on turbocharger.

♦ Coolant lines on turbocharger are not removed.
– Unscrew nuts and bolts -arrows-.

– Thread out heat shield -1- and remove it.
– Raise coolant line slightly when doing this.
Clamp position
– Mark installation position of clamp, turbocharger and catalytic
converter as shown. . Volkswag AG en AG
agen do
– The mark is to be madey Von
olkthe
sw component oppositeeto
s nothe
t gu
component to be renewed.
ise
d b ara
n r tee
ho
– Make sure thats athe
ut clamp is fitted at the same position on re‐ or
ac
installation. s
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
– Remove bolt -1- and nuts -arrows-.

t to the co
Vehicles with engine preheating element - Z97-

rrectness of i
– Unclip locking mechanism -arrow-.

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
o
by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Pull off wiring -1- on engine preheating element - Z97- -2-.
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
– Unscrew nuts -arrows- and remove engine preheating ele‐
wit
, is n
ment - Z97- with bracket.
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

or
thi
te
sd
a
– Unscrew bolts -arrows- of bracket.

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.
– Unscrew right nut -arrow- of bracket.

n AG. Volkswagen AG do Jetta 2015 ➤
wage
ks4-cylinder
Vol injection engine
es n
o(1.4
t gu l, 4V, EA211, turbocharger) - Edition 07.2019
d by ara
ise nte
– or -arrow- to the left of the bracket.
Unscrewuthnut eo
a ra
s c
– Remove tunnel cross-piece ⇒ General body repairs, exterior;
s
ce
le
Rep. gr. 66 ; Underbody cover; Removing and installing tunnel
un
pt
an
d
cross-piece .
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
– Detach connector from retainer and lay wire leading to Lamb‐

da probe to one side.
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.
– Loosen clamp -arrow-, and push it to rear.
– Remove catalytic converter with front exhaust pipe towards
rear.
– Insert screwdriver -2- in recess -arrow- on turbocharger.

– Lever out oil seal -1- and renew.
Installing
– Renew seal and self-locking nuts.
– Coat studs and bolts of catalytic converter with high-temper‐
ature paste; high-temperature paste ⇒ Electronic parts cata‐
logue (ETKA) .
– Align exhaust system free of stress ⇒ page 306 .
Torque settings
♦ ⇒ “2.1 Assembly overview - emission control”, page 309
♦ Underbody cladding; Removing and installing tunnel cross-
piece ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Removing and installing tunnel cross-piece .

Jetta 2015 ➤ agen
AG. Volkswagen AG d
oes
ksw
4-cylinder injection engine (1.4 l, 4V, bEA211,
yV
ol turbocharger) - Edition n07.2019
ot g
u ara
ed nte
oris e
th or
au
28 – Ignition system
ac
ss
ce
le
un
pt
an
d
itte
y li
1 Ignition system
rm
ab
pe
ility
ot
wit
⇒ “1.1 Assembly overview - ignition system”, page 314
, is n
h re
hole
⇒ “1.2 Test data, spark plugs”, page 315
spec
es, in part or in w
⇒ “1.3 Removing and installing ignition coils with output stage”,
t to the co
page 315
⇒ “1.4 Removing and installing knock sensor 1 G61 ”,
rrectness of i
page 318
l purpos
⇒ “1.5 Removing and installing Hall sender”, page 318

⇒ “1.6 Removing and installing engine speed sender G28 ”, page
nform
ercia
319
m
a
1.1 Assembly overview - ignition system
com
tion in
r
te o
thi
s
iva
do
1 - Bolt
r
rp
cum
fo
❑ The specified torque in‐
en
ng
t.
yi
fluences the function of
Co
op py
the knock sensor. t. C rig
gh ht
yri by
❑ 20 Nm op Vo
by c lksw
cted agen
Prote
2 - Knock sensor 1 - G61-
AG.

⇒ page 318
3 - Spark plug
❑ Change interval ⇒
Maintenance tables
❑ 22 Nm
4 - Ignition coil with output
stage and spark plug connec‐
tors
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
❑ To remove, use puller -
T10530- .
⇒ page 315
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
314 Rep. gr.28 - Ignition system

Jetta 2015 ➤
8 - O-ring
9 - Bolt
❑ 8 Nm
11 - O-ring
12 - Sender wheel
❑ For engine speed sender - G28-
13 - Sealing flange, gearbox side
14 - Engine speed sender - G28-
15 - Bolt
❑ 4.5 Nm
1.2 Test data, spark plugs

n AG. Volkswagen A G do
wage es n
olks o
Engine code by
V CZDA, CZTA t guar CZCA
ed an
ris tee
Firing orderutho 1-3-4-2
or
a ac
ss Spark plugs
ce
le
un
pt
VW part number 1)
⇒ Electronic parts catalogue (ET‐ ⇒ Electronic parts catalogue (ET‐
an
d
itte
KA) KA)
y li
erm
ab
Electrode gap 0.65 … 0.75 mm 0.70 … 0.80 mm

ility
ot p
wit
Change interval ⇒ Maintenance ; Booklet ; Service tables

is n
h re
ole,
spec
t to the co
1) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
1.3 Removing and installing ignition coils

rrectne
with output stage

s

s o
cial p
f i
♦ Puller - T10530-
nform
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.
1. Ignition system 315

Jetta 2015 ➤
Removing
Note
♦ The ignition coils are easier to remove when the engine is

warm.
♦ The grease added during installation of the ignition coils
makes it easier to remove them and the ignition plug connec‐
tors when the engine is warm.
. Volkswagen AG
gen AG
♦ When installing used ignition
ksw coils with output stage,
oes the igni‐
a d
not
Vol
tion coils need to beedlubricated
by with silicone paste ⇒ Electronic
gu
ara
parts cataloguetho(ETKA) .
ris nte
e or
au ac
♦ Ignition coilssswith output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
ce
e
nl
pt
du
(ETKA)
an
itte
y li
erm
ab
ility
Ignition coils “cyl. 2, 3, 4”
ot p
wit
, is n
h re
hole
spec
Continued for all ignition coils
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Push puller - T10530- as far as stop into hole in ignition coil
Co
Cop py
-1-. ht. rig
rig ht
py by
o Vo
– Tighten knurled nut -2- in -direction of arrow-. by c lksw
cted agen
Prote AG.

Jetta 2015 ➤
– Pull ignition coil out of camshaft housing in

-direction of arrow- using puller - T10530- .
Note
♦ Ignition coils with output stage and spark plug connectors are
available individually for repairs ⇒ Electronic parts catalogue
(ETKA)
♦ The spark plug connectors are removed from the ignition coils
by hand.
Installing
– Slide spark plug connector -1- by hand onto ignition coil as far
as stop.
The vent drilling -2- must be centred relative to connector housing

-3- while doing so.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Apply a thin bead of silicone paste around sealing hose of ig‐

nition coil.
nform
ercia
– Insert all spark plugs with spark plug connector loosely into
m
at
om
spark plug recess.

ion
c
in t
or
– Align ignition coils with connectors and simultaneously push

his
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⇒ “1.5.2 Removing and installing Hall sender 3 G300 ”,
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1.5.1 Removing and installing Hall sender -

G40-
Removing
– Unscrew bolt -2- and remove Hall sender - G40- .
Installing
– Install in reverse order of removal.
Torque settings
1.5.2 Removing and installing Hall sender 3 -

G300-
Removing

Jetta 2015 ➤

– Unscrew bolt -2- and remove Hall sender 3 - G300- .
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Torque settings
1.6 Removing and installing engine speed

sender - G28-
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D4B8047B934-4-Cylinder Injection Engine (1 4 L 4V EA211 Turbocharger)

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D4B8047B934-4-Cylinder Injection Engine (1 4 L 4V EA211 Turbocharger)

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Service

Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B8047B934

1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7 Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . . 37

1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.2 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.6 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

3.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

3.4 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 220

3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

3.3 Removing and installing resonator for intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

1.4 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

1.5 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible.

Before opening the fuel system:

– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connection

and carefully loosen the connection.

Danger of fire caused by escaping fuel

and cause a fire.

1.2 Safety measures when working on vehicles with start/stop system

1.4 Safety precautions when working on cooling system

– Wear protective gloves.

– Wear safety goggles.

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

running or being turned at starter speed.

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Vehicle data sticker .

Engine code CZCA CZDA h re

Displacement cm 3 1395 1395 1395

Torque Nm at 200/1400-4000 250/1500-3500 250/1400-3500

Compression ratio 10.0 10.0 10.0

Valves per cylinder 4 4 4

tional circumstances min. tional circumstances tional circumstances min.

91 RON, however with min. 91 RON, however 91 RON, however with

3.1 Rules for cleanliness

Use e.g. plugs from engine bung set - VAS 6122- .