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Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Tiguan 2008 ➤
Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, EA 111,
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turbocharger, supercharger)
Engine ID BLG BMY BWK
Edition 08.2017
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg K0058993820

Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran 2003 ➤
4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger) - Edition 08.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Specified AG. Volkswagen
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1.6 ris Additional information and assembly nwork tee for vehicles with air conditioner . . . . . . . . . . . . 16
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2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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2.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.6 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 28
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.1 Assembly overview - parts l and ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.2 Assembly overview - part I, belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1.3 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.4 Removing and installing poly V-belt (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 36
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1.5 Removing and installing poly V-belt (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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1.6 Removing and installing control housing (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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1.7 Removing and installing valve timing housing (Tiguan, Touran) . . . . . . . . . . . . . . . . . . . . 44

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1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 50

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2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2.2 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.3 Removing and installing crankshaft seal on belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . 53
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2.4 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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2.5 Removing and installing crankshaft sealing flange on flywheel end . . . . . . . . . . . . . . . . . . 58
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.4 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Contents i
1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.4 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . . 94
1.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Removing and installing parts of lubrication system . . a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. .do. . . . . . . . . . . . 121
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1.1 Engine oil, oil capacities, engine oil specificationby(engine Vol codes BLG, BMY) . .no.t g. u.a . . . . . 121
1.2 Engine oil, oil capacities, engine oil specification ed (engine code BWK) . . . . . . . . . . .ra.n . . . . 121
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1.3 Assembly overview . . . . . . . . . . . . . . . s.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a.c
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1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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1.1 Assembly overview - parts of cooling system, body side (engine codes BLG, BMY) . . . . 131
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1.2 Assembly overview - parts of cooling system, body side (engine code BWK) . . . . . . . . . . 132
1.3 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 133
1.4 Coolant hose schematic diagram (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . . . 135
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1.5 Coolant hose schematic diagram (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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1.6 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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1.8 Removing and installing radiator fan V7 and radiator fan 2 V177 (engine codes BLG, BMY)
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1.9 Removing and installing radiator (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . . . . . 142
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1.10 Removing and installing radiator and radiator fan V7 (engine code BWK) . . . . . . . . . . . . 144
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1.11 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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1.12 Removing and installing coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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1.13 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prote
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1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Releasing pressure in high-pressure area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.1 Fuel tank - assembly overview (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.2 Draining fuel tank (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.3 Removing and installing fuel tank (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.4 Assembly overview - fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.5 Draining fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.6 Removing and installing fuel tank (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.7 Assembly overview - fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.8 Draining fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.9 Removing and installing fuel tank (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.2 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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3.3 Removing and installing fuel delivery unit (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . 181
3.4 Removing and installing fuel gauge sender G (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . 183
3.5 Checking fuel pumps (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.6 Removing and installing fuel delivery unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.7 Removing and installing fuel gauge sender G (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.8 Checking fuel pump (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.9 Removing and installing fuel delivery unit (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.10 Removing and installing fuel gauge sender G (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.11 Removing and installing suction-jet pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.12 Removing and installing fuel gauge sender 2 G169 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 215
3.13 Checking fuel pump (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.14 Removing and installing fuel pump control unit J538 (Tiguan) . . . . . . . . . . . . . . . . . . . . . . 223
4 Repairing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.2 Removing and installing accelerator module (Golf, Golf Plus, Tiguan) . . . . . . . . . . . . . . . . 225
4.3 Removing and installing accelerator module (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.1 Assembly overview (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.2 Checking fuel tank breather (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
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5.3 Checking fuel tank breather (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.4 Assembly overview (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.5 Checking fuel tank breather (Tiguan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.2 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.3 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.5 Checking vacuum unit for turbocharger agen
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1.6 Removing and installing vacuum by
Vol unit for turbocharger . . .no.t .gu.a. . . . . . . . . . . . . . . . . . . . . . 246
d ra
1.7 Adjusting vacuum unit ofor ris turbocharger . . . . . . . . . . . . . . . . . . . n. te.e. . . . . . . . . . . . . . . . . . .
e 247
th o
2 Compressor . . . .ss.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . 254
2.1 Assembly overview - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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2.2 Removing and installing compressor (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 255
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2.3 Removing and installing compressor (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 263

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2.4 Removing and installing drive unit seal for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 271
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3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

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3.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

spec
3.2 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

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3.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . 281
rrectne
3.5 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

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1.1 Assembly overview - parts l and II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

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1.2 Assembly overview - part I, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

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1.3 Assembly overview - part II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

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1.4 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

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1.5 Checking vacuum reservoir for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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1.6 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

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1.7 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
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........................................................................ 298
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Contents iii
1.9 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1.10 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.11 Checking fuel pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.12 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
1.13 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.14 Renewing Teflon seal and support washer on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.15 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
1.16 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.17 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.1 Removing and installing enginencontrol AG. Volksunit
wageJ623
n AG d(Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . 320
age
2.2 Removing and installingVoanti-theft
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nJ623
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2.3 Removing and installing ed b engine control unit J623 (Golf Plus,
ra nteTouran) . . . . . . . . . . . . . . . . 323
ris
2.4 Removing and uinstalling
tho anti-theft engine control unit J623 (Golf e o Plus, Touran) . . . . . . . .
ra 324
a
2.5 Removing and s installing engine control unit J623 (Tiguan) . . . .c . . . . . . . . . . . . . . . . . . . .
s 326
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2.6 Removing and installing anti-theft engine control unit J623 (Tiguan) . . . . . . . . . . . . . . . . . . 328
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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1.1 Assembly overview - catalytic converter and attachments (engine codes BLG, BMY) . . . . 330
hole
spec
1.2 Assembly overview - catalytic converter and attachments (engine code BWK) . . . . . . . . . . 332
es, in part or in w
1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY) . . . . . . . . . . . . . . 333
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1.4 Assembly overview - silencer with mountings (engine code BWK) . . . . . . . . . . . . . . . . . . 334
1.5 Removing and installing front exhaust pipe (engine code BWK) . . . . . . . . . . . . . . . . . . . . 334
rrectness of i
1.6 Separating centre and rear silencers (engine codes BLG, BMY) . . . . . . . . . . . . . . . . . . . . 335
1.7 Separating centre and rear silencers (engine codes BWK) . . . . . . . . . . . . . . . . . . . . . . . . 337
l purpos
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 nform

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1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

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1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

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1.2 Problem solution for Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

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1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 341
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1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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iv Contents
00 – Technical data AG. Volkswagen AG d

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(VRL010627; Edition 08.2017)
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Engine number ⇒ page 1 e
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Engine data ⇒ page 1
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1.1 Engine number
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Engine code and engine number can be found on the sticker
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The engine code is also on the vehicle data sticker and on the
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The engine number consists of up to nine characters (alphanu‐
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“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.
Note
♦ Vehicles for certain export countries have no type plate. Fitting

locations for vehicle data sticker and identification plate:
♦ Golf, Golf Plus ⇒ Maintenance ; Booklet 38
♦ Touran ⇒ Maintenance ; Booklet 18.1
♦ Tiguan ⇒ Maintenance ; Booklet 24.1
1.2 Engine data

Engine code BLG BMY BWK
Manufactured
Golf 11.05► 02.06► ---
Golf Plus 11.05► 02.06► ---
Touran 11.05► 02.06► ---
Tiguan --- --- 10.07►
Exhaust emission stan‐ EU4 EU4 EU4
dard
Displace‐ cm3 1390 1390 1390
ment
Power kW at rpm 125/6000 103/6000 110/5800
1. Technical data 1
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➤ , Tiguan 2008 ➤ , Touran 2003ra➤ nte
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4-cylinder direct-injection
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engine (1.4 l, EA 111, turbocharger, supercharger) ra - Edition 08.2017
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Engine code BLG BMY BWK
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Torque Nm at rpm 240/1750-4500 220/1500-4000 240/1750-4000
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Bore ∅ mm 76.5 76.5 76.5
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Stroke mm 75.6 75.6 75.6
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Compression ratio 10 10 10
spec
RON min. 95 unleaded 95 unleaded 95 unleaded
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Injection, ignition Motronic MED 9.5.10 Motronic MED 9.5.10 Motronic MED 17
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
rrectne
Type of mixture formation Homogeneous Homogeneous Homogeneous
Charging Turbocharger and mechan‐ Turbocharger and me‐ Turbocharger and me‐
ss
ical supercharger chanical supercharger chanical supercharger
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2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Removing and installing engine
(Golf, Golf Plus, Touran)
Removing engine ⇒ page 3 .
Securing engine to assembly stand ⇒ page 13 .
Installing engine ⇒ page 13 .
Specified torques ⇒ page 15
Assembly mountings ⇒ page 16 AG. Volkswagen AG d
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Additional information and assembly work d by Vfor vehicles with air
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♦ Crankcases were installed with different size threaded holes.
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♦ Check these holes before dismantling/assembling and install
spec
the respective engine support.
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♦ The engine support - T40075- can continue to be used if con‐
verted as described in the respective work sequence.
rrectness of i
♦ The fitting of engine support - T40075- and engine support -
T40075A- on the crankcase is described in the respective
l purpos
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Converting engine support - T40075-
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– Scribe dimensions -a- and -b- as shown.

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Dimension -a- = 24.5 mm

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Dimension -b-: 49.0 mm

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– Mark position with a centre punch.

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– Identify engine support with an -A- behind tool designation. by c lksw
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1. Removing and installing engine (Golf, Golf Plus, Touran) 3

Special tools and workshop

equipment required
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♦ Engine support - T40075- with adapters /4, /5, /6 or engine

support - T40075A- (not illustrated) with adapters /4, /5, /6
rrectness of i
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-

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♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Engine and gearbox support - VAS 6095-
nform
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♦ Drip tray for workshop hoist - VAS 6208-

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4 Rep. gr.10 - Removing and installing engine

4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger,
agen
supercharger)
AG. Volkswagen AG
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♦ Pliers for spring-type clips - VAS 5024A-

♦ Stepladder - VAS 5085-
♦ Torque wrench (40 to 200 Nm) - V.A.G. 1332-
♦ Guide pins - T10093-
Note
The battery earth must be disconnected for the remaining proce‐

dure. Therefore, first check whether a coded radio is fitted. Then
obtain anti-theft coding first if necessary.
Engine cover panel ► November 2006

– Release vacuum hose on vacuum reservoir -arrow- and pull it

off.
– Lift engine cover panel at points -1- and pull it forwards in di‐
rection of -arrow-.
Engine cover panel, November 2006 ►
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– Pull vacuum hose off -arrow-.
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– Unbolt heat shield over turbocharger -arrows-.

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– Remove air filter ⇒ page 297 .
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– Open and close expansion tank cap to release pressure in
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– Drain coolant ⇒ page 136 . . C rig
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Note
AG.
Pull coolant hoses off engine with spring-type clip pliers - VAS
5024A- .
– Release hose guides -arrows- and remove coolant hose -1-

from coolant reservoir.
– Remove hose -2- from activated charcoal filter system

solenoid valve 1 - N80- to activated charcoal filter.

– Separate fuel supply line -1- and line to activated charcoal filter
-2-. Press release tabs to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 180 .
– Remove securing bolts -arrows- of engine splash protection.

– Remove front left and right wheel housing liners ⇒ General n AG. Volkswagen AG do
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
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– Bring lock carrier into service position ⇒ General
ut body repairs, or
ac
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exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
s
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The engine is removed downwards together with the gearbox.
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
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necting and reconnecting battery .
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– Remove battery and battery holder ⇒ Electrical system; Rep.
spec
gr. 27 ; Removing and installing battery .
es, in part or in w
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– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
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– Disconnect all electrical wiring from gearbox, alternator and
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starter and lay to side.

– Pull off or disconnect all other electrical connections as nec‐
nform
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essary from engine and lay to side.

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Fuel supply lines are under pressure! Wear eye protection and
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gloves to avoid injuries and skin contact. Wrap a cloth around

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lease pressure by carefully pulling hose off connection.
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– Pull vacuum and breather hoses off engine.
AG.
– Pull connectors off thermal switch and radiator fan.

– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Removing and installing anti-theft engine control unit (Golf) ⇒
page 321 .
– Removing and installing anti-theft engine control unit (Golf
Plus, Touran) ⇒ page 323 .

– Open all line guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.
Golf, Golf Plus only n AG. Volkswagen AG do
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– Remove hoses for activated charcoal filter -arrows-.
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– Pull activated charcoal filter -1- upwards out of bracket.

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– Unbolt bracket -arrows-.

Continued for all vehicles
– Remove wiring for Lambda probe after catalytic converter -
G130- and for alternator from cable guides -arrows-.

– Pull connector off Lambda probe after catalytic converter -

G130- and remove.
– Open hose clip -3- and remove charge air pipe -2-.
– Unbolt exhaust pipe from catalytic converter -arrows-.
satelettronica
– Unbolt exhaust pipe together with flexible joint -arrows-.
AG. Volkswagen AG d
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– Loosen securing bolts of double clamp -arrows- and pull ex‐

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haust pipe to rear.

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– Disconnect pendulum support -arrows-.

– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
– Remove strut -1-. AG. Volkswagen AG d
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– Detach slave cylinder -arrows- and place to one side. Do not
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– Remove hydraulic clutch slave cylinder: ⇒ 6-speed manual
t to the co
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism
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Note
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Do not depress clutch pedal.
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– Remove poly V-belt ⇒ page 36 .
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– Remove air conditioner compressor ⇒ Heating, air condition‐ atio

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The air conditioning system lines must not be opened.
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– Secure air conditioner compressor to lock carrier.
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– Ensure that lines are not kinked.
– Observe additional information and installation work ⇒ page
16 .
– Remove right drive shaft, and unscrew left drive shaft from
gearbox and tie up: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion
Work sequence with engine support - T40075-
Engine support - T40075- with adapters -/4-, -/5- and -/6- is re‐
quired to lower engine with gearbox.

– Screw adapter T40075/4 into crankcase to stop.

– Position engine support - T40075- with adapters -/5- and -/6-
on crankcase.
– Secure engine support - T40075- hand-tight to crankcase us‐

ing bolt -1-.
satelettronica
– Tighten all bolts on engine support - T40075- to 20 Nm.
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
Work sequence with engine support - T40075A-
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AG.
– Screw adapter T40075A/4 into crankcase to stop.

– Position engine support - T40075A- with adapters -/5- and
-/6- on crankcase.
– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.
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– Tighten all bolts on engine support - T40075A- to 20 Nm.
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– Unbolt gearbox side of assembly mounting from above

-arrows-.
Note
♦ To remove securing bolts use a stepladder - VAS 5085- .

♦ When lifted out, the engine/gearbox assembly must be care‐
fully guided to prevent damage to the bodywork.
– Carefully lower engine and gearbox.
1.2 Securing engine to assembly stand

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
Procedure
– Unbolt gearbox.
– Secure engine on engine and gearbox support - VAS 6095- .
satelettronica
1.3 Installing engine
Installation is carried out in the reverse order. When installing,
note the following:
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
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sleeve and splines on input shaft with G 000 100.

t to the co
– Check whether dowel sleeves for centring engine/gearbox

have been fitted in cylinder block, insert if necessary.
rrectne
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
s
– When swinging engine in, ensure that there is clearance be‐

s o
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tween drive shafts.

f inform
mer
Align engine mountings as follows:

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

support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
♦ On gearbox end, ensure that edges of support arm -2- and
gearbox bracket -1- are parallel.
– Install pendulum support.
satelettronica
Note
Specified torques for assembly mountings ⇒ page 16 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

shafts .
– Install air conditioning system compressor ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 36 . . Volkswagen AG
gen AG does
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– Electrical connections and routing: ⇒ Electrical
by
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– Install hydraulic clutch slave cylinder
s a ⇒ 6-speed manual gear‐
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– Attach selector mechanism ⇒ 6-speed manual gearbox 02S;

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Rep. gr. 34 ; Repairing selector mechanism .

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– Install engine splash protection.

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– Add coolant ⇒ page 136 .

hole
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– Install air filter ⇒ page 297 .

es, in part or in w
t to the co
– Install battery and battery tray ⇒ Electrical system; Rep. gr.

27 ; Removing and installing battery .
rrectness of i
– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

l purpos

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– Fit vacuum hose onto connection -arrow-.
– Connect vehicle diagnostic tester .
– Erase learnt values, and adapt engine control unit to regulating
flap control unit and throttle valve module ⇒ Vehicle diagnostic
tester “Guided Function”.
– Carry out vehicle system test ⇒ Vehicle diagnostic tester
“Guided fault finding”.
– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
– Perform road test.
– Then carry out vehicle system test again and rectify any faults
which may have occurred.
1.4 Specified torques

Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Note

1.5 Assembly mountings

Specified torques
Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 1) = 20 Nm + 90° (1/4 turn) further
B 1) = 40 Nm + 90° (1/4 turn) further
C 1) = 60 Nm + 90° (1/4 turn) further

1) Renew
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B 3) = 100 Nm + 90° (1/4 turn) further

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work for vehicles with air conditioner
Note
To prevent damage to condenser, refrigerant lines or hoses, en‐

sure that lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:

– Remove retaining clamp(s) for refrigerant lines.

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– Remove poly V-belt ⇒ page 36 . olkswage es n
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– Bring lock carrier into service position ⇒risGeneral
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– Remove air conditioner compressor ⇒ Heating, air condition‐
pt
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Securing engine to assembly stand ⇒ page 25 .
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Installing engine ⇒ page 25 .
Specified torques ⇒ page 27
rrectness of i
Assembly mountings ⇒ page 27
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Additional information and assembly work for vehicles with air

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2.1 Removing engine

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♦ Engine support - T40075 A- with adapters /4, /5, /6

♦ Engine and gearbox support - VAS 6095-
♦ Drip tray for workshop hoist - VAS 6208-

Note
The engine support - T40075- can continue to be used if convert‐

ed as described in the respective work sequence.
Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.
Dimension -a- = 24.5 mm
Dimension -b-: 49.0 mm
– Mark position with a centre punch.
– Drill a hole with a 13.0 mm bit.
– Identify engine support with an -A- behind tool designation.
satelettronica
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♦ Hose clamp pliers - VAS 6340-
2. Removing and installing engine (Tiguan) 19

♦ Stepladder - VAS 5085-

♦ Guide pins - T10093-
Note

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cooling system.
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– Remove hose -2- from activated charcoal filter system
AG.
solenoid valve 1 - N80- to activated charcoal filter.

– Seal lines so that fuel system is not contaminated by dirt.
– Depending on vehicle equipment, remove noise insulation or
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐
moving and installing noise insulation or skid plate .
– Remove front left and right wheel housing liners ⇒ General
body repairs; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
sition .
The engine is removed downwards together with the gearbox.
– Disconnect battery ⇒ Electrical
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or
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– All cable ties which are opened or cut through when engine is
nl
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– Pull off or disconnect all other electrical connections as nec‐
es, in part or in w
essary from engine and lay to side.

t to the co
WARNING
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– Pull vacuum and breather hoses off engine.

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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

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screen wiper system; Removing and installing wiper arms .

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yi Co
Cop py
.
– Remove plenum chamber cover: ⇒ General body repairs, ex‐
t rig
gh ht
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terior; Rep. gr. 64 ; Removing and installing plenum chamber cop Vo
by lksw
cover cted agen
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– Removing and installing anti-theft engine control unit ⇒

page 328 .

– Open all line guide fasteners -arrows-.

– Remove wiring from engine control unit.
– Secure lines/wiring to engine with a cable tie.

G130- and for alternator from cable guides -arrows-.
– Disconnect connector for Lambda probe after catalytic con‐
verter - G130- .
– Remove Lambda probe after catalytic converter - G130- -1-.
AG. Volkswagen AG d
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– Remove both drive shafts ⇒ Repairing drive shafts; Rep. gr.
h re
40 ; Removing and installing drive shafts .
hole
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es, in part or in w
t to the co
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– Remove securing bolts -1- and -2- for exhaust pipe mounting.
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– Remove exhaust pipe mounting downwards.

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– Loosen securing nuts of double clamp -arrows- and slide it

forwards on exhaust pipe -1-.
– Unscrew nuts -arrows- and pull exhaust pipe backwards.

– Push exhaust pipe backwards out of mounting -1-.
satelettronica
– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
AG. Volkswagen AG d
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– Lower subframe ⇒ Subframe, yV
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– Remove exhaust spipe
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– Remove gearbox carrier from bevel box ⇒ 6-speed manual
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gearbox 0A6; Rep. gr. 34 ; Removing and installing bevel box .

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– Unbolt selector mechanism from gearbox ⇒ 6-speed manual

pe
ility
gearbox 0A6; Rep. gr. 34 ; Repairing selector mechanism .

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– Remove hydraulic clutch slave cylinder hose -1-: ⇒ 6-speed

spec
manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐

es, in part or in w
draulic system .
t to the co
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Do not depress clutch pedal.

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⇒ page
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– Bring lock carrier
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tee
or
exterior; Rep.
au gr. 50 ; Body - front; Lock carrier service posi‐ ac
ss
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– Screw adapter T40075A /4 into the crankcase to stop.
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– Position engine support - T40075A- with adapters -/5- and
n
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– Secure engine support - T40075A- hand-tight to crankcase

using bolt -1-.
– Tighten all bolts on engine support - T40075A- to 20 Nm.

– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .

– Unbolt engine side of assembly mounting from above

-arrows-.
– Unbolt gearbox side of assembly mounting from above

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fully guided to prevent damage to the bodywork.
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– Carefully lower engine and gearbox.
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2.2 Securing engine to assembly stand
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carry out repairs.
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Procedure
– Unbolt gearbox.
ss o
– Secure engine on engine and gearbox support - VAS 6095- .
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2.3 Installing engine atio

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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
Prote AG.
vated charcoal filter system, coolant and refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐
sitions.
– Check clutch release bearing for wear and renew if necessary.

– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with G 000 100.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
satelettronica
♦ On gearbox end, ensure that edges of support arm -1- and
gearbox bracket -2- are parallel.
– Install gearbox carrier for bevel box ⇒ 6-speed manual
agen gear‐
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box 0A6; Rep. gr. 34 ; Removing and installing olksw
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First tighten securing nuts hand-tight.

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– Install exhaust pipe mounting and tighten securing bolts -1-

hole
spec
and -2- to 25 Nm.

es, in part or in w
t to the co
Specified torques for exhaust pipe ⇒ page 332 .

– Install subframe ⇒ Subframe, anti-roll bar, suspension links;
rrectness of i
Rep. gr. 40 ; Removing and installing subframe .

l purpos
– Install propshaft ⇒ Rear propshaft and final drive; Rep. gr.

39 ; Removing and installing propshaft .
nform
ercia
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

m
at
shafts .
om
ion
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– Attach selector mechanism ⇒ 6-speed manual gearbox 0A6;

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f
en
ng
manual gearbox 0A6; Rep. gr. 30 ; Assembly overview - hy‐

t.
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draulic system . C py
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cted agen
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– Install pendulum support.
Note
Specified torques for engine/gearbox assembly mountings ⇒

page 27
– Install air conditioning system compressor ⇒ Heating, air con‐

ditioning system; Rep. gr. 87 .
– Install poly V-belt ⇒ page 38 .
– Electrical connections and routing: ⇒ Electrical system;
olks
wRep.
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gr. 97 . db
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e
ris tee
– Add coolant ⇒ page 136 . tho or
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– Install battery and battery tray ⇒ Electrical system; Rep. gr.
itte
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erm
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– Reconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
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– Connect vehicle diagnostic tester .
l purpos
– Erase learnt values, and adapt engine control unit to regulating

flap control unit and throttle valve module ⇒ Vehicle diagnostic
tester “Guided Function”.
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– Carry out vehicle system test ⇒ Vehicle diagnostic tester

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2.4 Specified torques

Bolted connection Specified torque
Nuts and bolts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Note
2.5 Assembly mountings

Specified torques

Note
Securing bolts for engine/gearbox assembly mountings are

stretch bolts and must be renewed.
Engine mounting
A 4) = 20 Nm + 90° (1/4 turn) further
B 4) = 40 Nm + 90° (1/4 turn) further
C 4) = 60 Nm + 90° (1/4 turn) further

4) Renew
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B 5) = 40 Nm + 90° (1/4 turn) further
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2.6 Additional information and assembly

work for vehicles with air conditioner
Note

To facilitate removing and installing engine without opening re‐

frigerant circuit:


sition .
satelettronica
AG. Volkswagen AG d
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13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦ If metal shavings or larger quantities of metal particles or other

deposits (caused for example, by partial seizure of the conrod
bearings) are found in the engine oil when making repairs,
clean the oil passages thoroughly and renew the oil filter in
order to prevent further damage from occurring later.
♦ All bearing and running surfaces must be oiled before assem‐
bly.
Assembly overview - parts l and ll ⇒ page 30 .

Assembly overview - part I, belt drive ⇒ page 31 .
Assembly overview - part II, cylinder block ⇒ page 33 .
satelettronica
Removing and installing poly V-belt (engine codes BLG, BMY) ⇒
page 36 .
Removing and installing poly V-belt (engine code BWK) ⇒ page
38 .
Removing and installing valve timing housing (Golf, Golf Plus) ⇒
page 40 .
Removing and installing valve timing housing (Touran, Tiguan) ⇒
page 44
AG. Volkswagen AG d
Removing and installing ancillary bracket ⇒ page 48 . lksw
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1.1 Assembly overview - parts l and ll

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30 Rep. gr.13 - Crankshaft group

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1.2 Assembly overview - part I, belt drive
1. Dismantling and assembling engine 31

1 - 40 Nm + 1/4 turn (90°) fur‐

ther
❑ To loosen and tighten
securing bolt, counter‐
hold supercharger shaft
with spanner.
❑ Renew
2 - Pulley
❑ For supercharger
3 - 23 Nm
4 - Tensioning element
❑ For supercharger poly
V-belt
❑ Relieve tension with
spanner.
❑ Lock with locking pin -
T10060 A- .
5 - 8 Nm
satelettronica
6 - Coolant pump with magnet‐
ic clutch for supercharger -
N421-
❑ Removing and installing
⇒ page 146
❑ Removing and installing lkswage es n
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page 151 . tho tee
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16 mm open-end span‐
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spec
❑ Lock with locking pin - T10060 A- .

es, in part or in w
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Note
rrectness of i
♦ Vehicles with a manual gearbox:

idler roller installed instead of
l purpos
tensioning element.
♦ Specified torque for securing
nf
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bolt: 40 Nm.
rm
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9 - 23 Nm
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10 - Alternator
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❑ Contact surfaces must be free of oil and grease.
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12 - Securing bolt
❑ Renew
❑ Removing and installing crankshaft pulley ⇒ page 55
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.

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Golf 2004 ➤ , Golf Plus 2005 wage➤ , Tiguan 2008 ➤
n AG n AG d
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❑ Secure belt pulley against turning with - 3415- . counterhold
au
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❑ Turning further can be done in several stages.
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❑ The turning further angle can be measured with a commercial protractor.
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13 - 40 Nm + 1/4 turn (90°) further
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❑ Removing and installing with vehicle raised
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spec
14 - Air conditioner compressor
es, in part or in w
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15 - 23 Nm
rrectness of i
❑ For poly V-belt. l purpos
❑ Relieve tension with spanner.

❑ Lock with 4 mm Allen key.
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17 - Poly V-belt
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❑ Mark direction of rotation before removing.
on in
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❑ Removing and installing (engine codes BLG, BMY) ⇒ page 36 .

❑ Removing and installing (engine code BWK) ⇒ page 38 .
18 - Poly V-belt
❑ Mark direction of rotation before removing.
Caution
leys and tensioning ele‐
ments.
1.3 Assembly overview - part II, cylinder block

1 - Cylinder head with AG. Volkswagen AG d

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camshaft housing by
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❑ Removing and installing horis nte
eo
⇒ page 108 aut ra
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ss
❑ Do not rework sealing
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surface.
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❑ With integrated
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camshaft bearings.
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AMV 188 001 02 before es, in part or in w
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fitting.
❑ When installing, insert
rrectness of i
vertically from above so
that dowel pins fit into
l purpos
holes in cylinder head.

2 - Cylinder block
nf
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❑ Dismantling and assem‐
rm
m
bling cylinder block ⇒
atio
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satelettronica
page 50 .
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❑ Dismantling and assem‐
thi
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bling pistons and con‐

iv
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rods ⇒ page 71 .
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3 - Ancillary bracket
Co
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❑ For tensioning element
rig
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⇒ page 48
4 - Cover
5 - Sprocket
❑ For oil pump drive and
timing chain.
6 - 20 Nm + 1/4 turn (90°) further
❑ Renew
7 - Sprocket
❑ Lock sprocket using counterhold tool -T10172- .
8 - Drive chain
❑ Before removing, mark direction of rotation (installation position).
9 - 25 Nm
10 - Mounting pin
❑ Specified torque: 8 Nm
11 - Chain tensioner with tensioning rail
❑ For oil pump drive.
12 - Spring
13 - Sump
❑ Removing and installing ⇒ page 124
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 600 A2

14 - 13 Nm
15 - Piston
❑ For drive chain tensioner
16 - Compression spring
17 - Chain tensioner
18 - 9 Nm
19 - Valve timing housing
❑ Removing and installing (Golf, Golf Plus) ⇒ page 40
❑ Removing and installing (Touran, Tiguan) ⇒ page 44
❑ Install with sealant D 176 501 A1. n AG. Volkswagen AG do
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❑ When installing, install twoy V -M6x80- studs in camshaft housing
olk ot g
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or
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th or
au
20 - 10 Nm ss
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21 - Pulley
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❑ Note tightening sequence ⇒ page 55 .
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❑ Secure belt pulley against turning with counterhold - 3415- .
spec
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22 - Securing bolt
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❑ Contact surface for securing bolt must be free of oil and grease. nform
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❑ Secure belt pulley against turning with counterhold - 3415- .

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24 - O-ring t. Cop py
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25 - 50 Nm
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26 - Seal
27 - 40 Nm + 1/4 turn (90°) further
❑ Lock sprockets using counterhold - T10172- .
❑ Bolt with left-hand thread.
❑ Renew
28 - 50 Nm + 1/4 turn (90°) further
❑ Renew
29 - Tensioning rail
30 - Camshaft adjuster
❑ Must not be dismantled.
31 - Timing chain

32 - Sprocket
❑ For exhaust camshaft
❑ Lock sprockets using counterhold -T10172- .
33 - Slide rail
❑ For timing chain
34 - Guide pin
35 - Bearing bush
1.4 Removing and installing poly V-belt (en‐

gine codes BLG, BMY)
Special tools and workshop equipment required agen
AG. Volkswagen AG d
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♦ Locking pin - T10060 A- d by V gu
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♦ 16 mm open-end spanner - T10447-
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♦ 4 mm Allen key Prote AG.
Removing
Note
♦ Vehicles with an automatic gearbox, two tensioning elements

must be slackened to remove poly V-belt.
♦ Vehicles with a manual gearbox, idler roller installed instead
of upper tensioning element.


– Remove front right wheel housing liner ⇒ General body re‐
pairs; Rep. gr. 66 ; Wheel housing liner; Removing and in‐
stalling front wheel housing liner .
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swing tensioning element in

-direction of arrow- from below using 16 mm open-end span‐
ner.
– Lock tensioning element with a 4 mm Allen key -1-.
satelettronica
– To slacken poly V-belt, swivel tensioning element in direction
of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Lock tensioning element using locking pin - T10060 A- .
– Remove poly V-belt -2-.
Installing
AG. Volkswagen AG d
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Before installing poly V-belt,thensure that all ancillaries (alter‐ nte
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nator, air conditioner compressor)
s au are secured tightly. ra
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When installing poly V-belt, observe direction of rotation and
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make sure it is properly seated on pulleys and tensioning ele‐

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– Fit poly V-belt first over crankshaft pulley. Finally, push belt
h re
hole
onto tensioning roller.

spec
es, in part or in w
Further assembly is basically the reverse of the removal proce‐

t to the co
dure.
After completing repairs always:
rrectness of i
– Start engine and check belt running

l purpos
1.4.1 Poly V-belt routing

nform
mercia
at
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37
c by lksw
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Prote AG. 1. Dismantling and assembling engine
Belt drive with air conditioner compressor

1 - Pulley - cooling system pump
2 - Crankshaft pulley
3 - Tensioning pulley
4 - Tensioning roller or idler roller
5 - Alternator pulley
6 - Air conditioner compressor pulley
7 - Poly V-belt
Belt drive for supercharger
Note
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
satelettronica
for supercharger - N421- .
AG. Volkswagen AG d
1 - Supercharger pulley agen oes
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3 - Pulley - coolant pump with pulleyss- magnetic clutch for super‐
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charger - N421-
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4 - Poly V-belt
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1.5 Removing and installing poly V-belt (en‐

wit
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gine code BWK)

h re
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spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Locking pin - T10060 A-

rrectness of i
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en
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rig ht
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♦ 16 mm open-end spanner - T10447-
♦ 4 mm Allen key
Removing
Note
Two tensioning elements must be slackened to remove poly V-
satelettronica
belt.

– Drain coolant; to do this, pull hose -2- off.
Item -1- can be disregarded.
– Release retaining clip and pull right connection (as seen in n AG. Volkswagen AG do
direction of travel) off radiator. lkswage es n
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– Mark direction of rotation of poly V-belt. ir se nte
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– To slacken poly V-belt, swing tensioning element in

t to the co
-direction of arrow- from below using 16 mm open-end span‐

ner.
– Lock tensioning element with a 4 mm Allen key -1-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
en
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by
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– To slacken poly V-belt, swivel tensioning element in direction

of -arrow- from above using 16 mm open-end spanner -
T10447- .
– Remove poly V-belt -2-.
Installing
Caution
Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
When installing poly V-belt, observe direction of rotation and
make sure it is properly seated on pulleys and tensioning ele‐
ments.
AG. Volkswagen AG d
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– Fit poly V-belt first over crankshaft
rise
d
pulley. Finally, push belt nte
onto tensioning roller. autho eo
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dure.
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Add coolant ⇒ page 136 .
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1.5.1 Poly V-belt routing
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Belt drive with air conditioner compressor
1 - Pulley - cooling system pump
2 - Crankshaft pulley rrectnes
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nform
mer
5 - Alternator pulley
atio
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6 - Air conditioner compressor pulley

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Belt drive for supercharger
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Note Prote
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agen
♦ The pulley of the magnetic clutch for supercharger - N421- is

located behind the coolant pump pulley.
♦ The poly V-belt -4- runs over the pulley of the magnetic clutch
for supercharger - N421- .
1 - Supercharger pulley
3 - Pulley - coolant pump with pulley - magnetic clutch for super‐
charger - N421-
4 - Poly V-belt
1.6 Removing and installing control housing (Golf, Golf Plus)


equipment required
satelettronica
lkswage es n
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♦ Support - 10-222A-
♦ Adapter - 10 - 222 A /8-
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♦ Counter-hold tool - 3415-

♦ Pin - 3415/1-
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♦ Sealant D 176 501 A1

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1.6.1 Removing

Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touranag2003 en AG. ➤
Volkswagen AG
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olk supercharger) - Edition
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ris
– Remove engine splash protection. au
tho e or
ac
ss
ce
le
un
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
pt
an
d
itte
housing liner .
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erm
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– Mark the direction of rotation of the poly V-belt and remove
ility
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belt ⇒ page 36 .
wit
is n
h re
ole,
– Turn crankshaft in direction of engine rotation to TDC No. 1
spec
cylinder ⇒ page 79 .
t to the co
– Remove coolant pump ⇒ page 146 .
– Remove air conditioner compressor from bracket with refrig‐
rrectne
erant lines still connected ⇒ Heating, air conditioning; Rep.
gr. 87 .
ss
– Remove bracket for tensioning element and air conditioner
o
cial p
f
compressor.
inform
mer
– Remove alternator.
atio
om
– Install support device - 10 - 222 A- with adapter - 10 - 222 A /
n
c
i
or
n
8- as shown and hook into lifting eye.
thi
te
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satelettronica
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fo
en
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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.
– Take up weight of engine and remove securing bolts

-arrows-.
– Remove sump ⇒ page 124 .
– Now remove pulley securing bolt. Hold pulley with counterhold

- 3415- and -3415/1- .

– Remove Allen head bolt for control housing and hexagon bolts
indicated by -arrows-.
– Remove valve timing housing.
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Note that crankshaft bearing bush remains inausealing flange.
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1.6.2 Installing
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nform
ercia
Note
m
a
com
tio
♦ From model year 2009, a diamond coated washer is installed.
n in
r
The washer prevent the crankshaft from being turned when

te o
thi
the securing bolt is tightened.
s
iva
do
r
rp
cum
♦ Install a diamond coated washer -7- when a washer was not
fo
en
g
fitted as original equipment ⇒ Electronic Parts Catalogue “ET‐

n
t.
yi Co
op
KA”. C py
t. rig
gh ht
yri by
♦ The washer is fitted -7- between the bearing bush -5- and the cop Vo
by lksw
crankshaft sprocket. cted agen
Prote AG.
♦ Note that all contact surfaces from the securing bolt to the
crankshaft sprocket must be free of oil and grease.
– Clean sealing surfaces carefully. They must be free of oil and

grease.
1 - Securing bolt
2 - Crankshaft belt pulley
3 - Diamond coated washer (clipped onto crankshaft belt pulley)
4 - Crankshaft oil seal
5 - Bearing bush
6 - O-ring
7 - Diamond coated washer
Note
♦ The valve timing housing is still sealed to the engine with a

seal and also sealant D 176 501 A1.
♦ The sealant D 176 501 A1 is used to prevent leaks between
the valve timing housing and the joints -1- and -2-.
♦ Sealant spots must have a diameter of 10 mm and a thickness
of approx. 1 mm.

♦ Do not apply sealant until directly before the valve timing

housing is fitted.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Apply sealant D 176 501 A1 to the joints camshaft
rised housing/ nte
cylinder head -1- and cylinder head/cylinder
ut
ho block -2-. eo
ra
s a c
s
– Fit new gasket onto dowel pins.
ce
e
nl
pt
du
an
– When fitting, install two -M6x80- studs into cylinder head and
itte
y li
cylinder block as a guide.
erm
ab
ility
ot p
– Fit valve timing housing with crankshaft bearing bush simul‐
wit
, is n
taneously onto studs, dowel pins and crankshaft journal.
h re
hole
spec
– Tighten valve timing housing securing bolts evenly and diag‐
es, in part or in w
onally.
t to the co
Ensure that valve timing housing is not canted.
Specified torque:
rrectness of i
M6 bolt to 10 Nm
l purpos
M10 bolt to 50 Nm
nform
ercia
satelettronica
m
at
om
ion
c
in t
or
his
te

a
do
priv
cum
or

f
en
ng

t.
yi Co
Cop py
ht. rig
Install crankshaft belt pulley ⇒ page 55 . opy
rig by
Vo
ht
c lksw
by
cted agen
Prote
dure.
AG.
1.7 Removing and installing valve timing housing (Tiguan, Touran)

AG. Volkswagen AG d
agen oes
olks
w not
yV gu
equipment required
se
d b ara
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ri
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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
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
satelettronica
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /22- ( adapter - 10 - 222 A /26- must only
be used for Touran vehicles from November 2006 ►)
♦ Pin - 3415/1-
1.7.1 Removing


– Remove engine splash protection.
housing liner . AG. Volkswagen n AG do
wage es
olks of poly V-belt and remove
– Mark direction of rotation not belt.
yV gu b ara
ed n
Removing and thinstalling
or
is (engine codes BLG, BMY) ⇒ pagete36
eo .
au ra
Removing and
ss installing (engine code BWK) ⇒ page 38 . c
ce
e
nl
pt
du
an
itte
cylinder ⇒ page 79 .
y li
erm
ab
ility
ot p
wit
, is n
– Remove coolant pump ⇒ page 146 .
h re
hole
spec
– Remove air conditioner compressor from bracket with refrig‐
es, in part or in w
erant lines still connected ⇒ Heating, air conditioning; Rep.
t to the co
gr. 87 .
– Remove ancillary bracket.
rrectness of i
satelettronica
– Remove alternator.
l purpos
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /22-

(vehicles as of November 2006 ►: adapter - 10 - 222 A /26- )
nf
ercia
as shown in illustration, and hook it into lifting eye. orm

m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Take up weight of engine and remove securing bolts

-arrows-.

- 3415- and -3415/1- .

– Remove Allen head bolts for valve timing housing and

hexagon bolts indicated by -arrows-.
Note
Note that crankshaft bearing bush remains in sealing flange.
1.7.2 Installing
satelettronica
Note
♦ From model year 2009, a diamond coated washer is installed.

The washer prevent the crankshaft from being turned when
the securing bolt is tightened.
KA”. agen
AG. Volkswagen AG d
oes
w
olks not
♦ The washer is fitted -7- between the bearing bushd b -5- and the
yV gu
ara
crankshaft sprocket. orise nte
eo
h
ut ra
♦ Note that all contact surfaces from the securing
ss
a
bolt to the c
crankshaft sprocket must be free of oil and grease. ce
le
un
pt
an
d
itte
y li
erm
ab
grease. ility
ot p
wit
is n
1 - Securing bolt
h re
ole,
spec

t to the co

rrectne
5 - Bearing bush
6 - O-ring
ss o
cial p

inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
♦ The valve timing housing is still sealed to the engine with a

iva
o
r
seal and also sealant D 176 501 A1.

p
cum
r
fo
en
ng
♦ The sealant D 176 501 A1 is used to prevent leaks between

t.
yi Co
op
the valve timing housing and the joints -1- and -2-.
C py
t. rig
gh ht
yri by
♦ Sealant spots must have a diameter of 10 mm and a thickness cop Vo
by lksw
of approx. 1 mm.
cted agen
Prote AG.

lkswage es n
Golf 2004 ➤ , Golf by VPlus 2005 ➤ , Tiguan 2008 ➤ t, gTouran
o o
ua 2003 ➤
ed ran
horis engine (1.4 l, EA 111, turbocharger,
tee supercharger) - Edition 08.2017
aut or
a
ss c
♦ Do not apply sealant until directly before the valve timing
ce
e
nl
housing is fitted.
pt
du
an
itte
y li
erm
ab
ility
– Apply sealant D 176 501 A1 to the joints camshaft housing/
ot p
wit
cylinder head -1- and cylinder head/cylinder block -2-.
, is n
h re
hole
– Fit new gasket onto dowel pins.
spec
es, in part or in w
– When fitting, install two -M6x80- studs into cylinder head and
t to the co
cylinder block as a guide.
– Fit valve timing housing with crankshaft bearing bush simul‐
rrectness of i
taneously onto studs, dowel pins and crankshaft journal.
l purpos
– Tighten valve timing housing securing bolts evenly and diag‐

onally.
nf
ercia
Ensure that valve timing housing is not canted.
orm
m
atio
Specified torque:
om
n in
or c
M6 bolt to 10 Nm
thi
te
sd
iva
M10 bolt to 50 Nm
o
r
rp
cu
o
m
f
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
support and longitudinal member (right side). Prote AG.

Install crankshaft belt pulley ⇒ page 55 .
dure.
1.8 Removing and installing bracket for an‐

cillaries
Removing
Golf, Golf Plus, Touran

AG. Volkswagen AG d
agen oes
ksw
VGolf 2004 ➤ , Golf Plus 2005o➤ gu, Tiguan 2008 ➤ , Touran 2003 ➤
ol n t
d by ara
orise engine (1.4 l, EA 111, turbocharger, supercharger)
nte - Edition 08.2017
h eo
aut ra
c
– Remove securing bolts
ss -arrows- of engine splash protection.
ce
e
nl
pt
du
Tiguan
an
itte
y li
erm
ab
ility
skid plate ⇒ General body repairs, exterior; Rep. gr. 50 ; Re‐ ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove poly V-belt.
t to the co
Removing and installing (engine codes BLG, BMY) ⇒ page 36 .
rrectness of i
Removing and installing (engine code BWK) ⇒ page 38 .
l purpos
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

ing and installing alternator .
nform
ercia

ing system; Rep. gr. 87
m
at
om
ion
c
in t
or
Note
his
ate
do
priv
cum
or

f
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Ensure that lines are not kinked. by c lksw
cted agen
Prote AG.
– Unscrew securing bolts -1- and remove bracket.

Installing
– Fit ancillary bracket to cylinder block.
– Tighten securing bolts -1- to 25 Nm.

Specified torque for tensioning element ⇒ Item 13 (page 33)
dure.

AG. Volkswagen AG d
agen oes
ksw not
Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran by V 2003 ➤
ol
gu
ara
d
orise supercharger) - Edition 08.2017 nte
eo
th
au ra
ss c
ce
2 Removing and installing sealing
e
nl
pt
du
an
itte
flanges and flywheel or drive plate
y li
erm
ab
ility
ot p
Assembly overview ⇒ page 50
wit
, is n
h re
Removing and installing engine speed sender - G28- (engine
hole
spec
codes BLG, BMY, BWK) ⇒ page 51 .
es, in part or in w
t to the co
Removing and installing crankshaft seal on belt pulley end ⇒ page
53
Removing and installing crankshaft pulley ⇒ page 55
rrectness of i
Removing and installing crankshaft sealing flange on flywheel
end ⇒ page 58 l purpos
2.1 Assembly overview
nform
mercia
at
om
ion
c
Note
in t
or
his
ate
do
riv
Repairing clutch ⇒ Repairing clutch; Rep. gr. 30 ; Removing and

p
cum
or
installing clutch .
f
en
satelettronica
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
1 - Securing bolt cop Vo
by lksw
cted agen
❑ Removing and installing Prote AG.
crankshaft pulley ⇒
page 55
❑ Renew
❑ Contact surface for se‐
curing bolt must be free
of oil and grease.
❑ Secure pulley against
turning with counterhold
3415.
❑ The turning further an‐
gle can be measured
with a commercial pro‐
tractor.
2 - Pulley
❑ With diamond coated
washer
❑ Contact surfaces must
be free of oil and grease.
❑ Secure against turning
with counterhold 3415
when removing and in‐
stalling.
poly V-belt (engine
codes BLG, BMY) ⇒
page 36 .
poly V-belt (engine code
BWK) ⇒ page 38 .
3 - Seal
⇒ page 53
4 - Bearing bush

5 - O-ring
❑ Renew
6 - Cylinder block
7 - 60 Nm + 1/4 turn (90°) further
8 - Flywheel/drive plate
❑ When removing and installing flywheel, lock with counterhold - T10044- .
9 - Adapter
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
AG. Volkswagen AG d
agen oes
10 - 12 Nm yV
olksw not
gu
b ara
❑ Renew orised
nte
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11 - Sealing flange with sender
ss awheel and oil seal c
ce
le
❑ Removing and installing engine speed sender - G28- (not shown) ⇒ page 51 .
un
pt
an
d
❑ Specified torque for engine speed sender - G28- : 5 Nm.

itte
satelettronica
y li
erm
ab
❑ Renew sealing flange complete with oil seal and sender wheel only.
ility
ot p
❑ Removing and installing crankshaft sealing flange on flywheel end ⇒ page 58
wit
is n
h re
ole,
spec
2.2 Removing and installing engine speed sender - G28-
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.
2. Removing and installing sealing flanges and flywheel or drive plate 51


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
satelettronica
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
♦ Guide pin - T10341-

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
♦ Insert tool - T10370-
op Vo
by c lksw
cted agen
Prote AG.
Removing
– Remove compressor.
Removing and installing compressor (engine codes BLG, BMY)
⇒ page 255 .
Removing and installing compressor (engine code BWK) ⇒ page
263 .

– Pull off connector -1- from engine speed sender - G28- .

– Remove gasket -2- from cylinder block and remove engine
speed sender - G28- with socket - T10370- .
Installing
– Install engine speed sender - G28- and tighten securing bolt
to 5 Nm.
dure.
2.3 Removing and installing crankshaft seal on belt pulley end

equipment required
satelettronica
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Seal puller - 3203-

♦ Torque wrench - V.A.G 1332-
♦ Assembly sleeve - T10117/2-
♦ Assembly tool - T10053-
Removing


pairs; Rep. gr. 66 ; Removing and installing wheel housing
liner; Front wheel housing liner .
– Removing and installing crankshaft pulley ⇒ page 55 .
tool -3415- and -3415/1- .
– Remove centre bolt and remove crankshaft pulley.
– Screw inner part of oil seal extractor - 3203- three turns (ap‐
prox. 5 mm) out of outer part and lock using knurled screw.
satelettronica
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Remove bearing bush from crankshaft journal and clean con‐
tact surfaces of crankshaft sprocket and bearing bush.
Installing
Note
wage es n
♦ From model year 2009, a diamond coated washer yV
olks
is installed. ot g
ua
The washer prevent the crankshaft fromrisbeing
ed
b
turned when ran
tee
the securing bolt is tightened. utho
or
s a ac
s
ce
le

un
pt
an
d
KA”.
itte
y li
erm
ab
♦ The washer is fitted -7- between the bearing bush -5- and the
ility
ot p
crankshaft sprocket.
wit
is n
h re
ole,
♦ Note that all contact surfaces from the securing bolt to the
spec

t to the co

grease.
rrectne
1 - Securing bolt
ss

o
cial p
f inform

mer
atio

om
n
c
i
or
5 - Bearing bush
thi
te
sd
va
6 - O-ring
i
o
pr
cum
r
fo
en

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
54
cted agen
Prote AG.
Rep. gr.13 - Crankshaft group
. Volkswagen AG
swagen AG engine (1.4
does l, EA 111, turbocharger, supercharger) - Edition 08.2017
k not
Vol gu
d by a
– Pushorbearing
ise bush onto crankshaft journal. rante
th eo
au ra
ss c
– Fit sleeve -T10117/2- onto bush and slide oil seal onto bush.
ce
e
nl
pt
du
– Remove sleeve -T10117/2- from bush.
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
– Using assembly tool - T10053- , drive in oil seal into valve tim‐
ing housing as far as it will go with even blows of hammer.
nf
ercia
orm
m
atio
m
dure.
o
n in
or c
Removing and installing crankshaft pulley ⇒ page 55
thi
te
sd
satelettronica
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.
2.4 Removing and installing crankshaft pulley


equipment required
satelettronica
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
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.


♦ Pin - 3415/1- (not illustrated)
♦ Locating bolt - T10340-
♦ Dial gauge - VAS 6079-
♦ Dial gauge adapter - T10170-
Removing
Only Tiguan with all-wheel drive
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts .
satelettronica
– Loosen pulley securing bolt. Hold pulley with counterhold -
3415- and -3415/1- .
Installing
olkswagen AG
en AG. V
– Tighten pulley hand-tight using a new
olks securing bolt.
wag does
not
yV gu
db ara
ir se 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
cylinder.
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.

– Unscrew plug from crankcase.

– Screw locking pin - T10340- to stop into crankcase.
– Tighten locking pin - T10340- to 30 Nm.
Locking pin - T10340- locks crankshaft in direction of engine ro‐

tation.
AG. Volkswagen AG d
agen oes
olksw not
V
Note ed by gu
ara
ris nte
ho eo
ut
♦ Note that all contact
ss a surfaces from the securing bolt to the ra
c
ce
le
un
pt
satelettronica
an
d
♦ Always use a new bolt.

itte
y li
rm
ab
pe
ility
Specified torque: 150 Nm + 1/2 turn (180°) further.
ot
wit
, is n
h re
Hold pulley with counterhold - 3415- and -3415/1- .
hole
spec
es, in part or in w
t to the co
– Unscrew locking pin - T10340- from crankcase.
– Screw plug into crankcase.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
Specified torque: 30 Nm
n
t.
yi Co
Cop py
t.
– Install poly V-belt.
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
dure.
2.5 Removing and installing crankshaft sealing flange on flywheel end


equipment required
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
satelettronica
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
♦ Assembly tool - T10134- Cop py
ht. rig
rig ht
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- py by
co Vo
by lksw
cted agen
♦ Insert tool, 24 mm - V.A.G 1332/11- Prote AG.
♦ Hexagon bolts (Qty. 3) M6×35 mm

♦ Feeler gauge
♦ Depth gauge
2.5.1 Pressing sealing flange with sender

wheel off crankshaft
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.
Procedure
– Remove flywheel or drive plate as applicable.

– Set engine to TDC No. 1 cylinder ⇒ page 79

– Remove engine speed sender - G28- -arrow-.
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6×35 mm bolts.
– Screw three M6×35 mm bolts into threaded holes -arrows- of

. Volkswagen AG
sealing flange. swagen AG does
olk not
yV gu
– Screw bolts alternately (max. 1/2 turn (180°) ed for each bolt) into
b ara
nte
ris
sealing flange and press sealing flangeau
th together with sender
o eo
ra
satelettronica
wheel off crankshaft. 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
2.5.2 Pressing sealing flange with sender
wheel onto crankshaft
rrectness of i
l purpos
Note
nform
ercia
♦ The sealing flange with a PTFE seal is equipped with a sealing

m
lip support ring. This support ring serves as a fitting sleeve and
a
com
tio
must not be removed prior to installation.

n in
r
te o
thi
♦ Sealing flange and sender wheel must not be separated or

s
iva
do
turned after removal from packaging.

r
rp
cum
fo
♦ The sender wheel is held in its installation position on the as‐

en
ng
t.
yi
sembly device - T10134- by a locating pin.
Co
Cop py
t. rig
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♦ Sealing flange and oil seal form one unit and must only be yri
p by
o Vo
renewed together with the sender wheel.
c by lksw
cted agen
Prote AG.
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.

olkswagen AG
wag en AG. V
Golf 2004 ➤ , Golf Plusolks2005 ➤ , Tiguan 2008 ➤s n,oTouran
doe
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2003 ➤
yV
sed turbocharger, supercharger) - Edition
b ara 08.2017
n ri tee
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Assembly tool - T10134- ss
a ac
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nl
A - Clamping surface
pt
du
an
itte
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B - Hexagon nut
erm
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ility
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C - Assembly housing
wit
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D - Locating pin
hole
spec
E - Hexagon socket head bolt
es, in part or in w
t to the co
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
rrectness of i
l purpos
2.5.3 A - Assemble seal with sender wheel on

assembly tool - T10134- .
nf
ercia
orm
m
– Screw in hexagon nut -B- to just before clamping surface -A-
atio
m
of threaded spindle.
o
n in
or c
thi
te
sd
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cu
satelettronica
o
m
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on
hexagon nut -B- -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.
– Remove securing clip -arrow- from new sealing flange.
Note
Do not remove the sender wheel from the sealing flange or turn
it.

– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.
– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
satelettronica
– Upper edge of sender wheel and front edge of sealing flange
must align -arrows-.
lkswage es n
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ss ce
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un
pt
– Place sealing flange with front side on assembly tool - T10134-
an
d
itte
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so that locating pin -A- can be inserted in sender wheel hole
rm
ab
-A-.
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ility
ot
wit
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hole
Note
spec
es, in part or in w
t to the co
Ensure sealing flange lies flat on assembly tool.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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62
Prote AG.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
AG. Volkswagen AG d
agen oes
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2.5.4 B - Fitting assembly tool - T10134- with aut
ho eo
ra
c
s
sealing flange to crankshaft flange s
ce
le
un
pt
an
d
• Crankshaft flange must be free of oil and grease.

itte
y li
rm
ab
• Engine positioned at TDC No. 1 cylinder.
pe
ility
ot
wit
, is n
– Screw hexagon nut -B- to end of threaded spindle.
h re
hole
satelettronica
spec
– Press threaded spindle of assembly tool - T10134- in direction
es, in part or in w
of arrow, until hexagon nut -B- lies against assembly housing
t to the co
-A-.
– Align flat side of assembly housing on sump side of crankcase
rrectness of i
sealing surface.
l purpos
nform
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com
tion in
r
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– Secure assembly tool - T10134- to crankshaft flange using
thi
s
iva
hexagon socket head bolts -A-.
do
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Note Cop py
ht. rig
rig ht
py by
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
co Vo
by lksw
cted
prox. 5 full turns).
agen
Prote AG.
– To guide sealing flange, screw two M6 × 35 mm bolts -A- into

cylinder block.

2.5.5 C - Screwing assembly tool - T10134- on

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for petrol engines (red knob) -F- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
The guide pin for diesel engines (black knob) -D- must not be
inserted in threaded hole of crankshaft.
wage
e ks s no
Vol t gu
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– Hand-tighten both hexagonris
e socket head bolts of assembly nte
tool. utho eo
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ss
– Screw hexagon nut -E- onto threaded spindle by hand until it
ce
le
un
pt
lies on assembly housing -C-.
an
d
itte
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rm
ab
2.5.6 D - Pressing sender wheel onto
pe
satelettronica
ility
ot
wit
, is n
crankshaft flange using assembly tool -
h re
hole
T10134-
spec
es, in part or in w
t to the co
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
rrectness of i
l purpos
Note
nform
ercia
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
m
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tion in
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2.5.7 E - Checking sender wheel installation
yi Co
Cop py
. rig
position on crankshaft
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Ruler - T40100-

– Screw hexagon nut -E- to end of threaded spindle.

– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Turn Allen head bolt of Assembly tool - T10134- out of
crankshaft flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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nl
pt
du
– The sender wheel is in the correct installation position on the
an
itte
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
y li
erm
ab
flange -A- and sender wheel -B-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
– Set vernier gauge on crankshaft flange.

m
at
– Measure the distance »a« between crankshaft flange and
om
io
sender wheel.
n
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
If the engine and gearbox support - VAS 6095- does not provide Cop py
. rig
the necessary space, the ruler - T40100- should be placed on the
t
gh ht
yri by
crankshaft flange and the distance determined with a feeler cop Vo
by lksw
gauge.
cted agen
Prote AG.
If dimension »a« is too small:

– Re-press sender wheel ⇒ page 65 .
If dimension »a« is achieved:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 124 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90°).
2.5.8 f) Re-pressing sender wheel

– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
satelettronica
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G
1332/11- .
– Check installation position of sender wheel on crankshaft
again. ⇒ page 64
If dimension »a« is still too small:
– Tighten hexagon nut for assembly tool -AT10134-
G. Volkswagto
en45 Nm.
a o gen AG d
ksw wheel on crankshaftes not
– Check installation position of ysender
Vol gu
b
again ⇒ page 64 . ris
ed
ara
nt ee
tho or
s 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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
66
cted agen
Prote AG.
wage supercharger) - d
n AG. Volkswagen AG Edition
oe 08.2017
ks s no
Vol t gu
d by ara
e nte
ris
3 Crankshaft autho eo
ra
c
ss
ce
le
un
pt
an
d
itte
Pulling needle bearing out of and driving into crankshaft ⇒
y li
erm
ab
page 68 .
ility
ot p
Crankshaft dimensions ⇒ page 70 .
wit
is n
h re
ole,
spec
t to the co
1 - 50 Nm and 1/4 turn (90°)
further
rrectne
❑ Only tighten to 50 Nm
when measuring
ss
crankshaft radial clear‐
o
cial p
f
ance. Do not turn fur‐
inform
ther.
mer
atio
❑ Renew
om
n
c
i
2 - Bearing cap
or
n thi
te
satelettronica
sd
a
❑ Do not interchange
iv
o
pr
c
bearing caps (mark po‐
um
r
fo
sitions).
en
ng
t.
yi Co
op
❑ Bearing cap 3 with re‐ C py
t. rig
cesses for thrust wash‐
gh ht
pyri by
ers.
co Vo
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Prote
❑ Bearing shell retaining
AG.
lugs in cylinder block

and bearing caps must
align.
3 - Crankshaft
❑ Axial clearance (new):
0.07 ... 0.24 mm
❑ Wear limit: 0.26 mm
Check radial clearance with
Plastigage
❑ New: 0.03…0.05 mm
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Pulling needle bearing
out of and driving into
crankshaft ⇒ page
68 .
❑ Crankshaft dimensions ⇒ page 70 .
4 - Sealing flange with sender wheel and oil seal
❑ With engine speed sender - G28- (not illustrated).
❑ Specified torque for engine speed sender - G28- : 5 Nm.
❑ Renew sealing flange complete with oil seal and sender wheel only.
❑ Renewing crankshaft sealing flange - flywheel end ⇒ page 58 .
5 - 12 Nm
❑ Renew
6 - Thrust washers
❑ For bearing cap 3.
3. Crankshaft 67
❑ Note fixing arrangement
7 - Bearing shell
❑ In cylinder block
8 - Sprocket
❑ For oil pump drive and timing chain.
9 - Bearing shell
❑ In bearing cap.
❑ Do not interchange used bearing shells (mark).
3.2 Pulling needle bearing out of and driving

into crankshaft
Only vehicles with a dual clutch gearbox
satelettronica
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
lkswage es n
o ot g
byV ua
♦ Internal puller - VAS 251 635- ir se
d ran
tee
tho
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a ac
ss
ce
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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
♦ Drift - VW 207 C-
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.

Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
Installing
Note
The needle bearing must always be renewed after the gearbox

has been separated from the engine.
Condition:
• The front edges of the inner puller must not be chipped.
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-
-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-
-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
du
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itte
y li
erm
ab
ility
ot p
Installing
wit
, is n
h re
– Clean bearing seat in crankshaft and apply as thin coating of

hole
spec
grease.
es, in part or in w
t to the co
– Drive needle bearing into crankshaft to installation depth using

drift - VW 207 C- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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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.
3. Crankshaft 69
AG. Volkswagen AG d
agen oes
lksw not
Installation depth: dimension -a- = 2.0 mm byV
o gu
ara
ed
ris nte
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aut ra
Note ss c
ce
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nl
pt
du
an
If the needle bearing is inadvertently driven in too far, it must be
itte
y li
renewed because it will be damaged when it is pulled out again.
erm
ab
ility
ot p
wit
, is n
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
h re
box; Installing gearbox .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
3.3 Crankshaft dimensions
c
in t
r
satelettronica
o
his
ate
do
riv
Honing Crankshaft Conrod

p
cum
or
dimension in mm main journal ∅ journal ∅

f
en
ng
t.
yi Co
Basic dimension -0.022 -0.022 Cop py
54.00 47.80 ht. rig
rig ht
-0.037 -0.037
py by
co Vo
by lksw
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Stage I -0.022 -0.022 Prote AG.
53.75 47.55
-0.037 -0.037
Stage II --- -0.022
47.30
-0.037

4 Dismantling and assembling pistons

and conrods
Checking piston ⇒ page 72 .
Checking cylinder bores ⇒ page 73 .
Separating new conrod ⇒ page 73 .
Removing and installing pistons ⇒ page 74 .
Removing and installing oil spray jets ⇒ page 75 .
Note
All bearing and running surfaces must be oiled before assembly.
satelettronica
1 - Retaining ring
2 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift - 10 - 14- .
3 - Piston
❑ Checking ⇒ page
72
❑ Mark installation posi‐
tion and cylinder num‐ n AG. Volkswagen AG do
ber. wage es n
olks o t gu
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Caution
au
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Arrow on piston crown s
ce
e
nl
points to belt pulley end.

pt
du
an
itte
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erm
ab
❑ Install using piston ring

ility
ot p
clamp.
wit
, is n
h re
4 - Compression rings
hole
spec
❑ Offset gaps by 120°

es, in part or in w
t to the co
❑ Remove and install

compression rings with
piston ring pliers.
rrectness of i
❑ “TOP” faces towards

l purpos
piston crown.
❑ Checking ring gap ⇒
page 72 .
nform
ercia
❑ Checking ring-to-groove
m
at
om
clearance ⇒ page
ion
c
72 .
in t
or
his
te
5 - Oil scraper rings

a
do
priv
cum
❑ Carefully remove and

for
en
g
install 3-part oil scraper rings by hand.

n
t.
yi Co
op
❑ Checking ring gap ⇒ page 72 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Dismantling and assembling pistons and conrods 71

❑ Ring-to-groove clearance not measurable.
6 - Conrod bolt
❑ M7×0.75: 20 Nm + 1/4 turn (90°) further.
❑ M8×1: 30 Nm + 1/4 turn (90°) further.
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to corresponding specified torque but not further.
AG. Volkswagen AG d
agen
7 - Conrod bearing cap olks
w oes
not
byV gu
ara
❑ Due to the cracking method used to separate the bearing ris cap from the conrod in manufacture, thentcaps
e d
ee
only fit in one position and only on the appropriate conrod.
utho
or
s a ac
❑ Markings -A-: mark with cylinder number s
ce
e
nl
pt
❑ Markings -B-: mark paired conrods and conrod bearing caps
du
an
itte
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8 - Bearing shell erm
ab
ility
ot p
❑ Do not interchange used bearing shells.
wit
, is n
❑ Insert bearing shells centrally.
h re
hole
spec
Checking radial clearance with Plastigage:
es, in part or in w
t to the co
satelettronica
❑ New: 0.020 ... 0.060 mm
rrectness of i
❑ Do not rotate crankshaft when checking radial clearance.
l purpos
9 - Connecting rod
❑ Renew as set only.
nf
ercia
❑ Markings -A-: mark with cylinder number
orm
m
❑ Markings -B-: mark paired conrods and conrod bearing caps
atio
om
❑ Separating new conrod ⇒ page 73 .
n in
or c
thi
te
sd
iva
o
Caution
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cu
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f
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ng
The conrod must be re‐

t.
yi Co
installed in exactly the Cop py
. rig
same position as it was
t
gh ht
yri by
previously installed. cop Vo
by lksw
cted agen
Prote AG.
If new conrods are fitted,
then the choice of posi‐
tion is arbitrary.
❑ Guided axially by piston.
4.2 Checking piston

♦ External micrometer 75-100 mm - VAS 6071-
Checking piston
– Measure pistons approx 12 mm from the lower edge of skirt,
at 90° to the piston pin axis. Difference between actual and
nominal diameter max. 0.04 mm.
Piston ∅
Basic dimension mm 76.4601)
• 1) Measure approx. 12 mm from bottom of piston skirt

Checking piston ring gap

– Push ring squarely from above down into cylinder bore to ap‐
. Volkswagen AG
prox. 15 mm from bottom
swa
gend
en AGof cylinder. does
k not
Vol gu
by
Piston ring ris
ed New Wear alimit
ran
tee
dimensions inutmmho or
a ac
ss
1st compression ring 0.20 … 0.40 1.0
ce
le
un
pt
2nd compression ring 0.40 … 0.60 1.0
an
d
itte
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Oil scraper ring 0.20 … 0.80 ---7)
rm
ab
pe
ility
ot
7) No wear limit details available
wit
, is n
h re
hole
spec
Checking ring-to-groove clearance
es, in part or in w
t to the co
Clean annular groove before check.
Piston ring New Wear limit
rrectness of i
dimensions in mm
l purpos
1st compression ring 0.04 … 0.08 0.15

2nd compression ring 0.02 … 0.06 0.15
nform
ercia
satelettronica
Oil scraper ring Cannot be measured
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
4.2.1 Checking cylinder bores

fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
♦ Cylinder gauge - VAS 6078- (50…100 mm) cop Vo
by lksw
cted agen
Prote AG.
Checking cylinder bores
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm.
Cylinder bore ∅
Basic dimension mm 76.51
Note
Do not measure cylinder bores when cylinder block is mounted

on engine and gearbox support - VAS 6095- , as measurements
may be incorrect.
4.3 Separating new conrod

On new conrods it is possible that the breaking point is not fully
separated. If the conrod bearing cap cannot be removed by hand,
proceed as follows:
– Mark cylinder allocation of conrod ⇒ Item 9 (page 72) .

– Gently clamp conrod, as shown in illustration, in a vice with

soft aluminium jaws.
Note
♦ To prevent damage to the conrod, only clamp conrod in lightly.

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

ing cap in -direction of arrow- until it is loose.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
4.4 Removing and installing pistons au ra
ss c
ce
le
un
pt
an
d
itte
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♦ Drift - VW 222 A-
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
♦ Piston ring clamp, commercially available

tion in
r
te o
Removing
thi
s
iva
do
– Remove cylinder head ⇒ page 108 .

r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
– Mark piston installation position and corresponding cylinder
t. rig
gh ht
yri
number ⇒ Item 3 (page 71) . p by
co Vo
by lksw
cted agen
– Mark conrod installation position and corresponding cylinder Prote AG.
and conrod bearing cap ⇒ Item 7 (page 72) .

– Remove conrod bearing cap and withdraw piston and conrod
upwards.
Note

If the piston pin is difficult to move, heat the piston to approx. 60°
C.
– Remove retaining ring from piston pin eye.

– Drive out piston pin using drift - VW 222 A- .
Installing
Install in reverse order of removal, observing the following:
Note
Renew bolts that are tightened with turning further angle.
– Oil running surfaces of bearing shells.

– Install piston with commercially available piston ring clamp,
noting installation position ⇒ Item 3 (page 71) .
– Install conrod bearing cap, observing installation position ⇒
Item 7 (page 72) .
– Install cylinder head ⇒ page 108 .
satelettronica
Specified torques
♦ ⇒ “4.1 Assembly overview”, page 71
4.5 Removing and installing oil spray jets

♦ Insert tool - T10545-
Removing
– Unscrew bolts -arrows-. n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Remove sump ⇒ page 124 . ir se
d b ran
o tee
th
– Remove oil pump ⇒ page 126 . au or
ac
ss
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
ot p
♦ The crank web of the respective cylinder must be positioned

wit
is n
so that the socket - T10545- can be inserted in the pressure

h re
relief valve as close to vertical as possible.

ole,
spec
♦ Furthermore, the corners of the socket - T10545- and of the

t to the co
pressure relief valve must engage well.
– Turn crankshaft via vibration damper securing bolt in direction

rrectne
of engine rotation until the respective bolt is accessible.

ss o
cial p
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mer
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4-cylinder direct-injection engine
en AG. V (1.4al,geEA
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– Unscrew pressure relief ed valve -1-
b using Torx bit T40 - ara
nte
T10545- . oris eo
th
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– Remove oil spray
ss jets -2-.
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Installing
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Caution
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Risk of damage to oil spray jets.
hole
spec
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♦ Do not bend oil spray jets.
t to the co
♦ Check clearance of oil jets after reinstallation of pistons.
♦ Bent oil spray jets must be renewed.
rrectness of i
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1- Pressure relief valve - 27 Nm
orm
m
2- Oil spray jet
atio
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• Installation position: align leading edge of oil spray jet arrow

or
thi
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with machined surface of cylinder block.
satelettronica
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– Install oil pump ⇒ page 126 .
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– Install bolts -arrows-.

15 – Cylinder head, valve gear

1 Cylinder head
Note
olkswagen AG
en AG. V
♦ When installing olks an exchange cylinder head,
wag does
not all the contact
surfaces d between
byV the support elements, roller
gu rocker arms
ara
andhthe
orise
cams must be oiled before installing the ntecamshaft
eo
housing.
au
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c
ss
♦ The plastic protectors fitted to protect the open valves must be
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removed only immediately before the cylinder head is fitted.
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♦ If the cylinder head is renewed, all the coolant in the system
ility
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must also be renewed.
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♦ All bearing and running surfaces must be oiled before assem‐
hole
bly.
spec
es, in part or in w
♦ Dismantling and assembling intake manifold ⇒ page 288
t to the co
satelettronica
rrectness of i
Checking valve timing ⇒ page 79 .
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Adjusting valve timing ⇒ page 82

Checking timing chain ⇒ page 88
nf
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Removing and installing timing chain and drive chain for oil pump
atio
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⇒ page 94
o
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Removing and installing camshaft housing ⇒ page 103 .

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Removing and installing cylinder head ⇒ page 108 .

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Checking compression ⇒ page 111 .
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1. Cylinder head 77
1 - 8 Nm
2 - High-pressure pump
❑ For fuel supply.
❑ With fuel pressure regu‐
lating valve - N276- .
⇒ page 307
3 - Wiring guide
❑ Bolt to camshaft hous‐
ing with 8 Nm torque.
4 - To air filter
5 - 10 Nm
6 - Hall sender - G40-
❑ With O-ring
❑ Renew O-ring if dam‐
aged.
AG. Volkswagen AG d
❑ Problem solution if con‐ lkswagen oes
not
nector has slipped ⇒ d by Vo
satelettronica
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ara
page 340 orise nte
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7 - Stud, 6 Nm au ra
c
ss
ce
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8 - 10 Nm + 1/4 turn (90°) fur‐

un
pt
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❑ Renew
pe
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❑ Tighten from inside out‐

, is n
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wards.
hole
spec
9 - Camshaft case
es, in part or in w
t to the co

⇒ page 103
❑ Remove sealant
rrectness of i
residue.
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❑ Carefully clean sealing

surfaces. They must be oil and grease free.
nform
ercia
❑ Coat with D 154 103 A1 before fitting

m
❑ When installing, carefully fit onto dowel pins.

a
com
tion in
10 - 20 Nm
r
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11 - Lifting eye
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12 - Exhaust turbocharger
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13 - Oil pressure switch - F1- , 25 Nm C py
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rig ht
❑ Checking ⇒ page 128 py by
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❑ If seal is leaking, nip open and renew. cted agen
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14 - Cylinder head gasket

❑ Renew
❑ Metal gasket.
❑ After renewing, renew entire coolant.
15 - Cylinder head
❑ Check for distortion ⇒ page 79 .
❑ Sealing surfaces to camshaft housing must be oil and grease free.
❑ After renewing, renew entire coolant.
78 Rep. gr.15 - Cylinder head, valve gear

16 - Guide pin
17 - Dowel pin
18 - Oil strainer
❑ Inserted into cylinder head
❑ Renew
19 - Support element
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface
20 - Roller rocker fingers
❑ Check roller bearing for ease of movement.
❑ When installing, secure to supporting element using securing clip.
21 - Seal
Note
satelettronica
Note the different sealing types
when removing and installing the
camshaft housing ⇒ page 103 .
❑ Renew
❑ Qty. 4
❑ Inserted into cylinder head.
22 - Cylinder head bolt
AG. Volkswagen AG d
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❑ Follow installation instructionsed and sequence when loosening anduatightening
b ran ⇒ page 108 .
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23 - Roller tappet au ac
ss
❑ Lightly coat contact surface with engine oil.
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pt
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24 - O-ring
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❑ Renew
ility
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❑ Moisten with oil before inserting.

wit
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spec
es, in part or in w
Checking cylinder head for distortion

t to the co
Check with straightedge 500 mm - VAS 6075- and feeler gauge.

rrectness of i
Max. permissible distortion: 0.05 mm

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1.2 Checking valve timing

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1. Cylinder head 79

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

h re
hole
spec

es, in part or in w
t to the co

♦ Puller - T10094 A-
rrectness of i

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♦ Camshaft clamp - T10171 A-

nf
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Note
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The mounting points for securing the camshaft clamp were mod‐
or
thi
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ified. A new special tool designated camshaft clamp - T10171 A-

t
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has been introduced. Previous camshaft clamp - T10171- can

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continue to be used if processed as described in the following.

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– Place template -1- onto camshaft clamp - T10171- as shown.

– Mark camshaft clamp - T10171- at mark -2- using a centre
punch.
– Drill through camshaft clamp - T10171- using a 7 mm bit.
– Deburr hole on both sides.
– Additionally mark tool designation -T10171- with an »A«.
Test sequence
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B ⇒ page
341
– Unscrew coolant pipe securing bolts.
– Remove oil pressure switch using jointed wrench 24 mm -
T40175- . wage
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d by ara
– Screw dial gauge
ris
e
adapter -T10170- into spark plug hole nte to
stop. utho eo
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satelettronica
ss
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
ce
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pt
stop and lock in position with lock nut -arrow-.
du
an
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– Turn crankshaft in direction of engine rotation, to TDC No. 1

ab
cylinder. Note position of small needle on dial gauge. ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
The bores -arrows- in the camshafts must be as illustrated. If

l purpos
necessary, turn crankshaft one turn (360°) further.

nf
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Note
rm
m
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om
♦ If crankshaft is turned more than 0.01 mm past TDC, then turn

n in
or c
crankshaft back 45° against engine direction of rotation. Then

thi
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turn crankshaft in direction of engine rotation to TDC No. 1

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cylinder.
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♦ Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.

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when being turned back. cop Vo
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Caution
Before using camshaft clamp - T10171 A- you must check that

the pins on the tool project by at least 7 mm.
If this is not the case, the camshaft clamp is defective and must
be renewed.
Do not use any kind of hammer to position the camshaft clamp.
1. Cylinder head 81
. Volkswagen AG
4-cylinder direct-injection engine (1.4
ksw
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ag n AG111, turbocharger,
does supercharger) - Edition 08.2017
n ol ot g
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– Insert camshaft clamp -T10171orA-is to stop
e
in camshaft open‐ tee
ings. aut
h or
ac
ss
Locking pins -arrows 1- must engage in holes -arrows 2-. Inscrip‐
ce
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tion “TOP” -arrow 3- must be readable from above.
du
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itte
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If camshaft clamp -T10171 A- cannot be fitted into camshaft erm
ab
ility
openings to stop, then timing is incorrect and must be readjusted
ot p
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⇒ page 82 .
, is n
h re
hole
Timing is OK if camshaft clamp -T10171 A- can be fitted into
spec
camshaft openings to stop.
es, in part or in w
t to the co
dure. During this procedure, observe the following:
rrectness of i
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
l purpos
1.3 Adjusting valve timing
nf
ercia
orm
m
atio
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o
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equipment required
thi
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sd
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satelettronica
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♦ Counter-hold tool - T10172-
♦ Pin - T40011-
AG. Volkswagen AG d
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es, in part or in w
satelettronica
t to the co
rrectness of i
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nf
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♦ Locating bolt - T10340-
1. Cylinder head 83

Procedure
Removing and installing valve timing housing (Golf, Golf Plus) ⇒
page 40 .
Removing and installing valve timing housing (Touran, Tiguan) ⇒
page 44 .
– To turn crankshaft, reinstall bearing bush, crankshaft pulley
-2- and crankshaft bolt -3- and securely tighten crankshaft bolt
(use counterhold 3415).
– Remove spark plug from No. 1 cylinder. Use puller -T10094
A- and spark plug socket and extension 3122 B ⇒ page
341
AG. Volkswagen AG d
agen oes
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satelettronica
pt
an
d
itte
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rm
– Screw dial gauge adapter - T10170- into spark plug hole to
ab
pe
ility
stop.
ot
wit
, is n
– Screw dial gauge -VAS 6079- and extension -T10170/1- in to
h re
hole
spec
es, in part or in w
t to the co
cylinder. Note position of small needle on dial gauge.
– Then turn crankshaft back 45° opposite direction of engine ro‐
rrectness of i
tation.
l purpos
nform
mercia
a
– Press tensioning guide rail -1- in direction of arrow and lock
com
tio
piston with locking pin -T40011- .

n in
r
te o
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Mark direction of rotation of timing chain -3- using coloured felt

tip marker pen.
Note
Camshaft adjuster centre bolt -2- has a left-hand thread.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .
– Install camshaft adjuster -1- again.

– Renew bolts -2- and -4-. Tighten bolt -2- to 40 Nm and bolt
-4- to 50 Nm (use counterhold -T10172- ).
Caution

be renewed.
– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be pushed into holes in camshaft to stop.
Note
satelettronica
Do not push camshafts axially whilst turning.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
– Screw an M6 bolt hand-tight into corresponding
ss
a
bore ac
-arrows- (but do not tighten) to secure camshaft clamp -
ce
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nl
pt
du
T10171 A- .
an
itte
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erm
ab
ility
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Note
wit
, is n
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hole
Note that there are different securing points for the camshaft
spec
clamp - T10171 A- .
es, in part or in w
t to the co
– Remove camshaft sprocket bolts. It is absolutely necessary to
use counterhold -T10172- for this.
rrectness of i
l purpos
Note nform
ercia
Do not use camshaft clamp - T10171 A- as a counterhold.

m
at
om
io
– Remove one camshaft sprocket.

n
c
in t
or
his
e
– Place timing chain over camshaft sprockets, observing chain

at
do
riv
direction of rotation, and install camshaft sprocket again.

p
cum
for
en
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– Tighten camshaft bolts until camshaft sprockets can still just

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be turned on camshafts. Cop py
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– Tension timing chain by removing locking pin - T40011- . p by
co Vo
by lksw
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Prote AG.
1. Cylinder head 85

cylinder. Permissible deviation from TDC No. 1 cylinder:
±0.01 mm.
Note
If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then turn
crankshaft in direction of engine rotation to TDC No. 1 cylinder.
Only Tiguan with all-wheel drive

– Remove right drive shaft ⇒ Running gear, axles, steering;
drive shafts .
– Unscrew plug -arrow- from crankcase.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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nl
pt
du
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Locking pin - T10340- locks crankshaft in direction of engine ro‐

erm
ab
tation.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Hold camshaft sprockets -1- and -5- in this position with coun‐
m
at
om
terhold -T10172- then tighten bolt -2- (left-hand thread) to 40

on
c
in t
Nm and bolt -4- to 50 Nm.

or
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ate
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or
Note
f
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Crankshaft cannot move, and timing chain -3- must remain ten‐
t. C rig
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sioned on both sides when tightening camshaft bolts. p by
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by c lksw
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– Remove camshaft clamp -T10171 A- .

– Unscrew locking pin - T10340- from crankcase.

– Rotate crankshaft two full turns in direction of engine rotation
to TDC No. 1 cylinder. Permissible deviation from TDC No. 1
cylinder: ± 0.01 mm.
Caution

be renewed.
– Insert camshaft clamp -T10171 A- to stop in camshaft open‐

ings.
If camshaft clamp -T10171 A- cannot be fitted:
– Repeat adjustment. AG. Volkswagen AG d
agen
satelettronica
oes
ksw
If camshaft clamp -T10171 A- can be fitted by Vol not
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itte
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ab
ility
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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
– Remove camshaft clamp -T10171 A- , hold camshaft sprock‐

his
ate
ets with counterhold -T10172- and tighten bolts -2- (left-hand

do
priv
thread) and -4- a 1/4 turn (90°) further with a rigid wrench.
um
for
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ng
t.
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Cop py
Note
t. rig
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cted
Camshaft adjuster centre bolt -2- has a left-hand thread.
agen
Prote AG.
Note
Camshaft sprockets cannot move on camshaft whilst tightening.

1. Cylinder head 87
Note
The locking pin - T10340- remains in the crankcase until the

crankshaft pulley is installed.
♦ Installing valve timing housing (Golf, Golf Plus) ⇒ page 43 .

♦ Installing valve timing housing (Touran, Tiguan) ⇒ page 47
♦ Install crankshaft belt pulley ⇒ page 55 .
♦ Install poly V-belt.
♦ Removing and installing (engine codes BLG, BMY) ⇒ page
36 .
♦ Removing and installing (engine code BWK) ⇒ page 38 .
♦ Renew oil seals for camshaft sealing cover and oil them before
fitting.
1.4 Checking timing chain
satelettronica
♦ Torque wrench - VAS 6583- agen
AG. Volkswagen AG d
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♦ Tester for checking elongation of chain links - T10550-
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♦ Camshaft clamp - T10550/1- yri
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♦ Indicator - T10550/2-
agen
Prote AG.
♦ Scale sleeve - T10550/3-

• The engine oil temperature must be at least 40°C ⇒ Vehicle
diagnostic tester.
• The engine must necessarily not be at »TDC« position.
– Remove right front wheel ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .

– Remove noise insulation ⇒ Body, front; Rep. gr. 50 ; Noise

insulation; Assembly overview - noise insulation .
– Remove front right wheel housing liner: ⇒ General body re‐
housing liner .
Removing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
Removing poly V-belt (engine code BWK) ⇒ page 38 .
– Pull coolant hoses -1- off charge air pipe -2-, and clamp them
off using hose clips up to 40 mm - 3093- .
. Volkswagen AG
gen AG does
Vehicles with auxiliary/supplementary heater:
Vol
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– Open hose clips, and pull coolant
or
ise hoses off coolant pipes -1-. nte
h eo
ut ra
– Remove auxiliary/supplementary
ss
a heater with exhaust pipe c
and coolant hoses still connected ⇒ Auxiliary heater, supple‐
ce
e
nl
pt
mentary heater; Rep. gr. 82 ; auxiliary/supplementary heater;
du
an
itte
Removing and installing auxiliary/supplementary heater .
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erm
ab
ility
ot p
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satelettronica
, is n
h re
hole
spec
es, in part or in w
t to the co
Continued for all vehicles:
rrectness of i
– Pull off securing clip on charge air cooler in
l purpos
-direction of arrow-.
– Pull charge air hose -arrow- off charge air cooler.
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
– Remove securing bolt -arrow- for charge air pipe -1-.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 89
– Release and pull off connector -1- on oil level and oil temper‐
ature sender - G266- .
– Unclip bracket -2- on subframe for electric wire to oil level and
oil temperature sender - G266- .
– Unscrew securing bolt -arrow- for charge air pipe -1-.
satelettronica
– Lift off engine cover at points -1- and pull it forwards in direction
of -arrow-.
– Remove air filter housing ⇒ page 297 . agen
AG. Volkswagen AG d
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– Pull off fuel supply line -1- and line leading to activated char‐
es, in part or in w
coal filter -2- by pressing release tabs.

t to the co
rrectness of i
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– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.
– Unscrew hose clip -1- on charge air pipe.

– Open hose retainer -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3- and pull off con‐
nector from charge air pressure sender - G31- with intake air
temperature sender 2 - G299- .
– Remove bracket -4-.
satelettronica
AG. Volkswagen AG d
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olksw not
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– To do this, unscrew bolts -arrows-. ss a c
ce
le

un
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pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -arrows- and remove charge pressure sender -

G31- -1-.
nform
ercia
– Remove charge air pipe downwards.

m
a
com
ti
– Release connector -2- and pull off.

on 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
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by c lksw
cted agen
Prote AG.
1. Cylinder head 91
Disregard item -1-.
– Remove bolts for both camshaft covers -3-.

– Unclip wiring harness -1-.
– Pull coolant pipe -2- and wiring harness -1- away from cylinder
head.
– Lever both camshaft covers -3- out of cylinder head.
satelettronica
– The hole in the left exhaust camshaft -left arrow- must be po‐
sitioned as shown in the illustration.
wage es n
– If necessary, turn crankshaft in direction of engine yrotation.
Volks ot g
u b ara
ed nte
oris e
th or
au ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
– Insert camshaft clamp - T10550/1- to stop in camshaft open‐

t to the co
ings.
– The locking pin -arrow A- must engage in hole -arrow B- in
rrectness of i
exhaust camshaft.
l purpos
– Inscription “TOP” must be readable from above.

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

– Bolt on camshaft clamp - T10550/1- hand-tight.

– Use one bolt of the camshaft covers for this purpose -arrow-.
– Screw indicator - T10550/2- into hole in sump.

– Align centring point vertically so that the tip faces upwards.
– Tighten centring point with knurled nut.
satelettronica
– Position scale sleevege-nT10550/3-
AG. Volkswagon
en Abelt
G d pulley. a oes
ksw not
Vol gu
d by ara
Caution
ris
e nte
tho eo
s au ra
c
Theresis a risk of injury caused by trapping fingers.
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nl
pt
du
The scale sleeve - T10550/3- is equipped with magnets.

an
itte
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erm
ab
Proceed with great care when joining the components.

ility
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Note that the components are drawn together quickly by the

wit
, is n
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magnetic force.
hole
spec
es, in part or in w
t to the co
– Align scale sleeve - T10550/3- with indicator - T10550/2- as

shown in illustration.
rrectness of i
– Apply torque wrench - VAS 6583- with a suitable socket to

l purpos
crankshaft bolt.
– Push torque wrench - VAS 6583- clockwise and maintain a
nf
ercia
torque of 40 Nm on it.
orm
m
– Set scale sleeve - T10550/3- and indicator - T10550/2- to »0«.

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
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 93
– Switch setting of torque wrench - VAS 6583- , and push it

slowly anti-clockwise.
– Maintain a torque of 40 Nm on torque wrench - VAS 6583- .
– Read value on the scale.
– If the chain skips during the test, renew timing chain ⇒ page
94 .
– If the chain skips, it can be heard and felt clearly.
Evaluation of the test olkswage es n
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byV ua
– If a chain elongation rof ise up to 28° has been determined duringante
d r
the test, the timinguthchain is OK.
o eo
ra
a c
ss
– If a chain elongation of 29° and more has been determined,
ce
e
nl
the timing chain is not OK and must be renewed ⇒ page
pt
du
an
94 .
itte
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erm
ab
Assemble in reverse order of dismantling. During this procedure,
ility
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observe the following:
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
satelettronica
♦ The scale sleeve - T10550/3- is equipped with magnets.
rrectness of i
♦ Do not use any levers for removing the scale sleeve -
T10550/3- from the belt pulley!
l purpos
– Turn scale sleeve - T10550/3- towards right by approx. 45° so

nform
ercia
that indicator - T10550/2- is not positioned within range of

scale.
m
at
om
io
– Grasp behind scale sleeve - T10550/3- with both hands.

n
c
in t
or
his
e
– Press thumbs against bolt of belt pulley, and pull off scale
at
do
riv
sleeve - T10550/3- .
p
cum
for
en
g
– Renew oil seals for camshaft sealing cover and oil them before
n
t.
yi Co
fitting. t. Cop py
rig
gh ht
yri
– Add coolant ⇒ page 136 . p by
co Vo
by lksw
cted agen
Specified torques Prote AG.
♦ ⇒ “1.7 Removing and installing air filter”, page 297

♦ ⇒ “2.1 Assembly overview”, page 114
♦ ⇒ “3.1 Assembly overview - charge air system”, page 275
♦ ⇒ “2.1 Assembly overview - supercharger”, page 254
♦ ⇒ “1.2 Assembly overview - part I, belt drive”, page 31
♦ ⇒ Body, front; Rep. gr. 50 ; Noise insulation, Assembly
overview - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and
installing wheel housing liner .
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
1.5 Removing and installing timing chain and chain drive for oil pump


equipment required
lkswage es n
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byV ua
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tho
u or
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un
pt
an
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itte
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erm
ab
ility
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wit
is n
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ole,
spec
satelettronica
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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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 lksw
by
cted agen
Prote AG.
♦ Pin - T40011-
1. Cylinder head 95

Removing

off.
rection of -arrow-.
satelettronica
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss
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le
un
pt
an
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itte
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rection of -arrow-.
rm
ab
pe
ility
ot
wit
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– Drain coolant ⇒ page 136 . h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove coolant hoses and line/wiring guides -arrows-.

nform
ercia
– Unscrew securing bolts and remove camshaft sealing

m
covers -1-.
a
com
tion in
– Remove spark plug from No. 1 cylinder. To do this, use puller

r
te o
thi
- T10094 A- and spark plug socket and extension - 3122 B- ⇒

s
iva
do
page 341 .
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cum
fo
en
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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.

– Screw dial gauge adapter - T10170- into spark plug hole to

stop.
– Screw dial gauge - VAS 6079- and extension -T10170/1- in to
cylinder. Note position of small needle on dial gauge.
The bores -arrows- in the camshafts must be as illustrated. If

necessary, turn crankshaft one turn (360°) further.
Note
♦ If crankshaft is turned more than 0.01 mm past TDC, then turn

crankshaft back 45° against engine direction of rotation. Then
turn crankshaft in direction of engine rotation to TDC No. 1
satelettronica
cylinder.
♦ Permissible deviation from TDC No. 1 cylinder: ± 0.01 mm.
Caution

. Volkswagen AG
If this is not the case, the camshaft clamp is defective and
ksw
amust
gen AG does
be renewed. by
Vol not
gu
ara
d
ise nte
Do not use any kind of hammer to position the
thocamshaft clamp.
r eo
au ra
c
ss
ce
e
nl
pt
du
an
– Insert camshaft clamp - T10171 A- to stop in camshaft open‐
itte
y li
erm
ings. 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
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sd
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 97
– Screw an M6 bolt hand-tight into corresponding bore

-arrows- (but do not tighten) to secure camshaft clamp -
T10171 A- .
Note
Note that there are different securing points for the camshaft
clamp - T10171 A- .
– Remove the control housing (Touran, Tiguan) ⇒ “1.7 Remov‐

ing and installing valve timing housing (Tiguan, Touran)”, page
44
– Remove the control housing (Golf, Golf Plus) ⇒ “1.6 Removing
and installing control housing (Golf, Golf Plus)”, page 40 .
– Pull cover -1- off sprocket for oil pump.
AG. Volkswagen AG d
agen
satelettronica
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
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wit
– Press tensioning rail in -direction of arrow- by hand and lock
, is n
h re
piston of chain tensioner with locking pin - T40011- .
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
– Mark direction of rotation of timing chain -3- using coloured felt

thi
te
tip marker pen.

sd
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Note
Co
Cop py
t. rig
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Camshaft adjuster securing bolt -2- has a left-hand thread.
op Vo
by c lksw
cted agen
Prote AG.
– Remove bolts -2- and -4- and remove camshaft adjuster -1-
with timing chain -3-. Counterhold using counterhold -
T10172- .

– Hold oil pump sprocket with counterhold - T10172- and loosen

securing bolt -1-.
– Use a screwdriver on bolt -2- to release tensioning spring -1-

then remove tensioning spring -1-.
– Unscrew securing bolt -3- and remove chain tensioner.
– Mark direction of rotation of oil pump drive chain -2- using felt-
tip marker.
satelettronica
– Remove securing bolt for sprocket -1- and remove
sprockets -1- and -3- together with drive chain for oil pump
-2-.
Installing
• The crankshaft must be positioned at TDC No. 1 cylinder.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Push sprocket -1- in -direction of arrow- onto crankshaft jour‐
ce
le
un
pt
nal as far as the stop.

an
d
itte
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erm
ab
ility
ot p
Caution
wit
is n
h re
ole,
Cast lug -2- on sprocket -1- must seat in groove -3- on

spec
crankshaft journal.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
t. rig
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pyri by
99
co Vo
by lksw
cted 1. Cylinder head
agen
Prote AG.
– Mark position of sprocket and crankshaft to cylinder block us‐

ing a felt-tip marker.
AG. Volkswagen AG d
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olksw not
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ris nte
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nl
pt
du
an
itte
– Place oil pump drive chain -3- onto sprocket -1- while posi‐
y li
erm
ab
tioning sprocket -2- on oil pump drive shaft.
ility
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wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ Note running direction mark on oil pump drive chain.
♦ Oil pump drive sprocket only fits on oil pump drive shaft in one
satelettronica
position -arrow-.
rrectness of i
l purpos
nf
ercia
or
– Hold oil pump drive sprocket with counterhold - T10172- .
m
m
atio
m
– Tighten new securing bolt -1- to 20 Nm + 1/4 turn (90°) further.

o
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Position chain tensioner on oil pump drive chain and tighten

securing bolt -3- to 8 Nm.
– Lever tensioning spring -1- onto bolt -2- using a screwdriver.
Note
♦ Note marks -arrows-.

♦ The crankshaft must remain stationary.
– Tighten sprocket -3- hand-tight with new securing bolt.

– Place timing chain -1- on crankshaft

en AG. V
olkswagen AGsprocket -4-, exhaust
camshaft sprocket
olkswag-3-, and tighten camshaft
does adjuster -2- hand-
not
tight using
ed ba
y Vnew securing bolt. gu
ara
ris nte
utho eo
ra
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ss Note
ce
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nl
pt
du
an
itte
♦ Note running direction mark on timing chain -1-.
y li
erm
ab
♦ Ensure guide sleeve is installed between inlet camshaft and
ility
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camshaft adjuster.
wit
, is n
h re
hole
♦ Camshaft adjuster securing bolt -2- has a left-hand thread.
spec
es, in part or in w
t to the co
Timing chain must lie on guide rail -1- and crankshaft sprocket
-arrow-.
rrectness of i
l purpos
nform
mercia
at
satelettronica
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Install chain tensioner -1- and tighten securing bolts -2- to
C py
t. rig
9 Nm.
gh ht
pyri by
Vo
co lksw
by
– Tension timing chain by pulling locking pin - T40011- out of
cted agen
Prote AG.
chain tensioner.
– Check marks on crankshaft sprocket and cylinder block; they
must align.
– Tighten securing bolt -2- to 40 Nm and bolt -4- to 50 Nm (use

counterhold -T10172- ).
Note
♦ Securing bolts -2- and -4- are only tightened 90° further once
timing has been checked.
♦ The camshaft adjuster securing bolt -2- has a left-hand thread.
1. Cylinder head 101

– Unscrew bolt -arrow- and remove camshaft clamp - T10171

A- from camshaft housing.
– Check valve timing ⇒ page 79
If valve timing is OK:
– Hold camshaft wheels with counterhold -T10172- and tighten

bolts -2- (left-hand thread) and -4- a 1/4 turn (90°) further with
a rigid wrench.
Note
Camshaft adjuster securing bolt -2- has a left-hand thread.
satelettronica
Note
Camshaft sprockets cannot move on camshaft whilst tightening.
olkswagen AG
– Install oil pump wheel cover
swa
g-1-.
en AG. V does
olk not
V gu
– Install valve timingsehousing
db
y
(Touran, Tiguan) ⇒ “1.7 Removing ara
nte
and installing valve
hori
timing housing (Tiguan, Touran)”, page eo
ut
44 . ss a ra
c
ce
e
– Install valve timing housing (Golf, Golf Plus) ⇒ “1.6 Removing

nl
pt
du
an
and installing control housing (Golf, Golf Plus)”, page 40 .

itte
y li
erm
ab
– Install crankshaft pulley ⇒ “2.4 Removing and installing

ility
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crankshaft pulley”, page 55 .

wit
, is n
h re

hole
spec
Removing and installing (engine codes BLG, BMY) ⇒ “1.4 Re‐

es, in part or in w
t to the co
moving and installing poly V-belt (engine codes BLG, BMY)”,

page 36 .
rrectness of i

l purpos
– Place vacuum hose -2- onto vacuum reservoir union -1-.

nform
mercia
at
om
io
Note
n
c
in t
or
his
te
a
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.

en AG. V
supercharger) - Edition 08.2017
olkswagen AG
ag does
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Vol gu
– Push engine cover panel down at points ed -1- in direction
by of ara
nte
-arrow- until it engages. thoris eo
au ra
Engine cover panel, November 2006
ss ► c
ce
le
un
pt
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
ss
o
cial p
f in
form
mer
dure.
atio
om
n
c
i
or
n thi
satelettronica
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sd
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Cop py
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Vo
o
1.6 Removing and installing camshaft housing
by c lksw
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
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un
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rm
♦ Dial gauge - VAS 6079- ab

pe
ility
ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co

rrectness of i
♦ Pin - T40011-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
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.


1.6.1 Removing
Note
♦ The camshafts are mounted in the camshaft housing on this

engine. Before removing
wage
n AG.the
Volkcamshaft
swagen AG housing, first remove
does
the valve timing
yV
olkshousing. not
satelettronica
bg ua
ed ra
♦ Removingho
ris and installing valve timing housing (Golf,
nte
eGolf Plus)
⇒ page
s aut 40 . or
ac
s
♦ Removing and installing valve timing housing (Touran,
ce
e
nl
pt
du
Tiguan) ⇒ page 44 .
an
itte
y li
erm
ab
♦ The camshaft housing sealing surface cannot be reworked.

ility
ot p
wit
, is n
– First check whether a coded radio is fitted. If so, obtain anti-

h re
hole
theft code.
spec
es, in part or in w
– With ignition switched off, disconnect battery earth strap.

t to the co

rrectness of i

– Remove coolant hoses and line/wiring guides -arrows-.
l purpos
– Unscrew securing bolts and remove camshaft sealing

nform
ercia
covers -1-.
m
– Remove turbocharger ⇒ page 238 .

at
om
ion
c
– Remove valve timing housing ⇒ page 40 .

in t
or
his
ate
– Turn crankshaft to TDC No. 1 cylinder. Then, turn crankshaft

do
priv
back 45° against direction of engine rotation, and remove

um
for
camshaft sprockets with timing chain ⇒ page 82 .

en
ng
t.
yi Co
op py
– Unbolt camshaft sealing covers. t. C rig
gh ht
pyri by
– Pull connectors off fuel pressure sender for low-pressure -
o Vo
by c lksw
cted
G410- and off high-pressure pump.
agen
Prote AG.
– Unscrew earth cable from camshaft housing.

– Remove ignition coils. Use puller -T10094 A- for this purpose
⇒ page 341 .
– Remove cable guide with wiring harness from camshaft hous‐
ing.
WARNING


– Pull connector and fuel supply line -arrows- off high-pressure

pump.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
satelettronica
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
– Loosen union nuts -3- and -1- of high-pressure line.

– Disconnect connector off Hall sender - G40- .
AG. Volkswagen AG d
– Pull out oil dipstick. agen oes
o lksw not
y V gu
d b ara
– Loosen camshaft housing orisbolts
e from outside to inside, alter‐ nte
nately and diagonally aand
ut
h remove. eo
ra
ss c
– Carefully lift camshaft housing off.
ce
le
un
pt
an
d
itte
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1.6.2 Installing
erm
ab
ility
ot p
Condition
wit
is n
h re
ole,
• The pistons cannot be positioned at TDC.

spec
– Remove sealant residues from cylinder head and camshaft

t to the co
housing with a rotating brush, e.g. a hand drill with a plastic

brush (wear eye protection).
rrectne

grease.
ss
– Also prevent dirt and residual sealant from entering cylinder

o
cial p
head.
inform
mer
atio
Caution
om
n
c
i
or
n thi
e

t
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
be renewed. t. Cop py
rig
gh ht
Do not use any kind of hammer to position the camshaft clamp. pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Turn inlet and exhaust camshafts until camshaft clamp -

T10171 A- can be pushed into holes in camshaft to stop.
– Secure camshaft clamp -T10171 A- hand-tight with an M6 bolt
(do not tighten).
Sealing on cylinder head with no sealing ring in area of spark plug
recess
AG. Volkswagen AG d
agen oes
olksw not
V
Caution ed by gu
ara
ris nte
ho eo
ut
No sealant is applied inssarea of the oil strainer -1-.
a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
– Apply thin, even coat of sealant on clean camshaft housing
ab
ility
sealing surface. See yellow area in illustration.
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Sealant cannot be applied too thickly; otherwise excess sealant
can enter oil channels and cause damage to engine.
satelettronica
rrectness of i
Sealing on cylinder head with sealing ring in area of spark plug
l purpos
recess
– Place new seals into grooves in cylinder head.
nf
ercia
orm
m
atio
Caution
om
n in
or c
thi
No sealant is applied in area of the oil strainer -1-.
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
– Apply thin, even coat of sealant on clean camshaft housing Cop py
t. rig
sealing surface. See yellow area in illustration. opyri
gh by
Vo
ht
by c
– Do not apply sealant in area of -arrows-.
lksw
cted agen
Prote AG.
Note
Sealant cannot be applied too thickly; otherwise excess sealant

can enter oil channels and cause damage to engine.
Caution
Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective sup‐
port elements -2-.
Proceed with extreme caution when fitting the camshaft hous‐
ing onto the cylinder head in order to prevent the roller rocker
fingers from sliding down!

AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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– When fitting camshaft housing onto cylinder head, first fit
erm
ab
camshaft housing at angle shown in illustration onto dowel
ility
ot p
pins -arrows-.
wit
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spec
es, in part or in w
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satelettronica
rrectness of i
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– Then, carefully lower camshaft housing in

m
at
om
-direction of arrow- towards cylinder head.
ion
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or
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Note
p
cum
for
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t.
Ensure that no oil residue can drip onto sealing surfaces.
yi Co
Cop py
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rig ht
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– Evenly tighten new camshaft housing securing bolts from in‐ copy Vo
by lksw
side to outside alternately and diagonally. cted agen
Prote AG.
Ensure that camshaft housing is not canted. Specified torque: 10

Nm + 1/4 turn (90°) further.
Note
After installing the camshaft housing, wait about 30 minutes for

the sealant to dry.
– Adjust valve timing ⇒ page 82 .

♦ Install turbocharger ⇒ page 238 .
♦ Install crankshaft belt pulley ⇒ page 55 .
♦ Attaching fuel lines ⇒ page 307
1.7 Removing and installing cylinder head


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Support - 10 - 222 A-
l purpos
♦ Adapter - 10 - 222 A /8- (Golf, Golf Plus)

nf
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♦ Adapter - 10 - 222 A /22- (Touran, Tiguan)

orm
m
atio
♦ Bracket - T10358-
om
n in
c

or
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a

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Removing
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op
Remove following components:
C py
t. rig
gh ht
yri by
♦ Removing and installing valve timing housing (Golf, Golf Plus)
op Vo
by c lksw
⇒ page 40 .
cted agen
Prote AG.
♦ Removing and installing valve timing housing (Touran,

Tiguan) ⇒ page 44
♦ Remove thermostat housing from cylinder head.
♦ Remove timing chain and drive chain for oil pump ⇒ page
94 .
♦ Remove turbocharger ⇒ page 238 .
♦ Remove regulating flap control unit - J808- and throttle valve
module - J338- ⇒ page 298 .

♦ Removing intake manifold ⇒ page 288 .

– Unscrew securing bolt for gearbox and attach bracket -
T10358- as shown. AG. Volkswagen AG d
agen oes
lksw not
– Attach hooks of support bracket - 10 - 222 A- to bracket - d by
Vo gu
ara
T10358- as shown. orise nte
h eo
ut ra
– Turn spindle until the hooks are lightly tensioned. ss a c
ce
le
un
pt
an
d
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Unhook hook -1- from left lifting eye and push spindle onto left
side of support bracket - 10 - 222 A- .
rrectness of i
– Remove roller rocker fingers together with support elements
l purpos
and lay aside on a clean surface.
satelettronica
– Ensure that roller rocker fingers and support elements are not
nform
ercia
interchanged.
m
a
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tion in
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– Loosen cylinder head bolts in sequence given and then re‐ op
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move completely.
C py
t. rig
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yri by
– Carefully remove cylinder head.
op Vo
by c lksw
cted agen
Prote AG.
Installing
Condition
• The pistons cannot be positioned at TDC.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
– Now carefully clean sealing surfaces of cylinder head and
cylinder block. When doing this, ensure that surfaces are not
scored or scratched (if sand paper is used, grade must not be
less than 100).
– Carefully remove metal particles, emery residue and cloths.
– Set no. 1 cylinder piston to top dead centre and then turn
crankshaft back slightly.
– Fit new cylinder head gasket. Inscription (Part No.) must be
readable.
– Fit cylinder head. When doing this, observe centring pins in
cylinder block.
– Insert new cylinder head bolts and tighten hand-tight.

– Tighten cylinder head in sequence as follows:

Specified torque/turning further angle
Stage Specified torque
1 30 Nm
2 Turn 90° further using rigid
wrench
wrench
wrench
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Install camshaft housing.
satelettronica
dure.
1.8 Checking compression
AG. Volkswagen AG d
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du
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erm
ab
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wit
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spec
es, in part or in w
t to the co
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Cop py
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111
cop Vo
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Prote
cted AG.
agen 1. Cylinder head

equipment required
satelettronica
AG. Volkswagen AG d
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un
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♦ Compression tester - V.A.G 1763-

rrectness of i
Prerequisites for check

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• The engine oil temperature must be at least 30 °C.

Procedure
nform
ercia

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a
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tio
– Remove ignition coils. Use puller -T10094 A- for this purpose.

n in
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te o
thi
– Remove spark plugs using spark plug socket 3122 B ⇒

s
iva
do
page 341 .
r
rp
cum
fo
en
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
ng
t.
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er; fuse assignment ⇒ Current flow diagrams, Electrical fault Cop py
finding and Fitting locations.
t. rig
gh ht
pyri by
Vo
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by c
– Check compression using compression tester - V.A.G 1763- .
lksw
cted agen
Prote AG.
Note

How to use the test unit is described in the respective operating

instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10 … 15 bar
Wear limit: 7 bar
Maximum permissible difference between all cylinders: 3 bar
– Insert spark plugs with spark plug spanner 3122B and tighten
to 25 Nm.
dure.
– Read fault memory, rectify any faults and then erase fault
memory: ⇒ Vehicle diagnostic tester “Guided fault finding”.
The readiness code must be generated if the fault memory has
been erased.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
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ate
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.

2 Repairing valve gear

Checking camshaft axial clearance ⇒ page 115 .
Reworking valve seats ⇒ page 116 .
Checking valve guides ⇒ page 117
Renewing valve stem seals ⇒ page 118
1 - 40 Nm and 1/4 turn (90°)

further
❑ Left-hand thread
❑ Renew
2 - Camshaft adjuster
❑ Must not be dismantled.
satelettronica
⇒ page 82
AG. Volkswagen AG d
agen oes
3 - Camshaft sprocket Vol
ksw not
gu
by ara
❑ Note position when in‐ ris
ed
nte
stalling timing chain.
utho eo
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a c
ss
4 - O-ring
ce
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nl
pt
du
❑ Renew if damaged
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❑ Before installing, coat

erm
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ility
lightly with engine oil.

ot p
wit
, is n
5 - Inlet camshaft control valve

h re
hole
1 - N205-
spec
es, in part or in w
6 - 10 Nm
t to the co
7 - 10 Nm + 1/4 turn (90°) fur‐

ther
rrectness of i
❑ Renew
l purpos
❑ Tighten from inside out‐

wards.
nform
ercia
8 - Camshaft case
m
at

om
ion
⇒ page 103
c
in t
or
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❑ Remove sealant
at
do
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residue.
p
cum
or
❑ Coat with D 154 103 A1

f
en
ng
t.
yi
before fitting
Co
Cop py
t. rig
❑ When installing, fit verti‐ yri
gh by
ht
cally from above onto studs and dowel pins.
op Vo
by c lksw
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Prote
9 - 10 Nm
AG.
10 - Sealing cover
❑ For inlet camshaft
❑ For exhaust camshaft
11 - Roller rocker fingers
❑ Check roller bearing.

❑ When installing, secure to supporting element using securing clip.
12 - Cotters
13 - Valve stem seal
❑ Renew
14 - Support element
❑ Check oil spray holes.
❑ With hydraulic valve clearance compensation.
❑ Before installing, check camshaft axial clearance ⇒ page 115 .
15 - Valve guide
❑ Checking ⇒ page 117
16 - Valve springs
❑ To remove and install with cylinder head removed, use valve spring tool - 3362- .
❑ With cylinder head installed ⇒ page 118 .
17 - Cylinder head
satelettronica
❑ Reworking valve seats ⇒ page 116 .
❑ Reworking sealing surface ⇒ page 115 .
18 - Valves
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ page 116
AG. Volkswagen AG d
19 - Exhaust camshaft ksw
agen oes
not
Vol gu
❑ Do not interchange with inlet camshaft. ed
by ara
nte
ris
❑ Checking axial clearance ⇒ page 115 . ut ho eo
ra
a c
❑ Coat with oil before inserting (also axialssbearing shoulder).
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nl
pt
du
20 - Guide bush
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itte
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erm
ab
21 - Inlet camshaft
ility
ot p
❑ With cam for high-pressure pump -arrow-.
wit
, is n
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❑ Before removing, remove and renew bucket tappet for high-pressure pump.
hole
spec
❑ Do not interchange with exhaust camshaft.
es, in part or in w
t to the co
❑ Checking axial clearance ⇒ page 115 .
❑ Coat with oil before inserting (also axial bearing shoulder).
rrectness of i
22 - 50 Nm + 1/4 turn (90°) further

l purpos
Reworking cylinder head sealing surface

nform
ercia
Cylinder head reworking dimension: a = at least 108.25 mm

m
at
om
ion
c
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Note
at
do
priv
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or
When the sealing surface has been reworked, the valves must be
f
en
ng
t.
set deeper by the same amount (valve seat inserts reworked) or
yi Co
op py
valves will contact pistons. When doing this, ensure that the per‐ t. C rig
gh ht
missible minimum dimension is maintained ⇒ page 116 . yri
p by
co Vo
by lksw
cted agen
Prote AG.
2.2 Checking camshaft axial clearance
2. Repairing valve gear 115


♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Perform measurements with camshaft housing removed and cap
fitted.
Checking camshaft axial clearance
Wear limit: max. 0.40 mm
Valve dimensions
Note
satelettronica
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Outlet valve AG. Volkswagen AG d

agen oes
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∅a mm 29.5 26.0 byV
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∅b mm 5.973 5.953 tho r eo
au ra
c mm 100.9 100.5ss c
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α ∠° 45 45
un
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ab
2.3 Reworking valve seats
pe
ility
ot
wit
, is n
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spec
♦ Depth gauge
es, in part or in w
t to the co
♦ Valve seat refacing tool
rrectness of i
Note
l purpos
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
nform
ercia
mileage engines, it is necessary also to check valve guides for

wear ⇒ page 117 .
m
a
com
tion in
♦ Valve seats are only to be reworked to the extent required to

r
te o
yield a proper surface appearance. Before beginning to rework

thi
s
iva
valve seats, calculate the maximum permissible reworking di‐

do
r
rp
mensions. If the reworking dimension is exceeded, the hy‐

um
fo
draulic valve clearance compensation can no longer be

en
ng
t.
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guaranteed and the cylinder head must be renewed. . Cop py
rig
ht ht
rig by
py
The max. permissible reworking dimension is calculated as fol‐
co Vo
by lksw
cted
lows:
agen
Prote AG.
– Insert valve and press firmly against seat.
Note

. Volkswagen AG
gen AG
If the valve is to be renewed asVopart
lksw of a repair, use a newesvalve
a do
not
for the calculation. ed by gu
ara
ris nte
utho eo
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– Measure distance
ss abetween end of valve stem and upper edge c
of cylinder head.
ce
le
un
pt
an
d
– Calculate maximum permissible reworking dimension from
itte
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measured distance and minimum dimension.
erm
ab
ility
ot p
Minimum dimension: inlet valve 7.6 mm, exhaust valve 7.6 mm
wit
is n
h re
ole,
Measured distance minus minimum dimension
spec
= max. permissible reworking dimension.
t to the co
Example:
-Measured distance 8.0 mm
rrectne
Minimum dimension 7.6 mm
=Max. permissible reworking dimension8) 0.4 mm
ss o
cial p
8) The max. permissible reworking dimension is shown as dimension “b” in the
f in
illustrations for reworking valve seats.
form
mer
atio
m
Reworking inlet valve seat

o
satelettronica
c
i
or
n
a = 28.7 mm diameter
thi
te
sd
a
b = max. permissible reworking dimension1

iv
o
pr
c
c = 1.5 … 1.8 mm
um
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fo
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ng
= cylinder head lower edge

t.
yi Co
α = 45° valve seat angle Cop py
β
t. rig
= 30° upper correction angle yri
gh ht
γ
by
= 60° lower correction angle cop Vo
by lksw
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Prote AG.
9) Calculating max. permissible reworking dimension ⇒ page 116 .
Reworking exhaust valve seat
a 25.0 mm ∅
b = max. permissible reworking dimension1
c = approx.1.8 mm
Z = cylinder head lower edge
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
10) Calculating max. permissible reworking dimension ⇒ page 116 .
2.4 Checking valve guides

♦ Dial gauge
Test sequence

– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐ gen AG. Volkswagen AG d
a
ters, only use inlet valve in inlet guide and exhaust valve Volin
ksw
oes
not
gu
exhaust guide. ed by ara
n ris tee
– Determine rock. Wear limit: 0.8 mm utho or
a ac
ss
If the amount of sideways play is exceeded:
ce
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nl
pt
du
an
– Renew cylinder head.
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
2.5 Renewing valve stem seals
rrectness of i
♦ Spark plug socket - 3122B-
l purpos
nform
ercia
satelettronica
m
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Valve stem pliers - VAS 6770-
♦ Valve spring tool - 3362- with thrust piece - 3362/1-

♦ Valve stem seal fitting tool - 3365-

lkswage es n
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byV ua
d ran
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tho
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a ac
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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
♦ Pressure hose - VW 653/3-
rrectness of i
l purpos
nf
ercia
orm
satelettronica
m
atio
om
n in
or c
thi
te
sd
iva
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m
f
en
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t.
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op py
Removing t. C rig
gh ht
pyri by
(With cylinder head installed)
co Vo
by lksw
cted agen
Prote AG.
– Remove camshaft housing ⇒ page 103 .
– Remove roller rocker fingers and place onto a clean surface.
When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Remove spark plugs with spark plug spanner -3122B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Attach valve spring tool - 3362- with thrust piece - 3362/1- .
– Now screw pressure hose -VW 653/3- into spark plug hole.
– Connect pressure hose to compressed air system supplying
at least 6 bar and remove valve springs.
– Pull off valve stem seals using valve stem pliers - VAS 6770- .
Installing

– Place plastic sleeve supplied on respective valve stem. This

will prevent damage to new valve stem seal.
– Place new valve stem seal in valve stem seal fitting tool -
3365- .
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
– Install camshaft housing ⇒ page 106 .
♦ Install fuel lines ⇒ page 307
satelettronica
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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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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ate
do
priv
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

17 – Lubrication
1 Removing and installing parts of lu‐
brication system
AG. Volkswagen AG d
agen oes
Note y Volksw not
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d b ara
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♦ Finding metal shavings or a largeutho quantity of small metal par‐ eo
ra
ticles during engine repair could
ss a
indicate that the conrod bear‐ c
ings are damaged. To prevent this from causing further
ce
le
un
pt
damage, perform the following repairs:
an
d
itte
y li
rm
♦ Thoroughly clean oil channels.
ab
pe
ility
ot
♦ Renewing oil filter
wit
, is n
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♦ The oil level must remain below the max. mark - danger of
hole
spec
damage to catalytic converter! Markings ⇒ page 124 .
es, in part or in w
t to the co
Engine oil, oil capacities, engine oil specification (engine codes
satelettronica
BLG, BMY) ⇒ page 121
rrectness of i
Engine oil, oil capacities, engine oil specification (engine code
l purpos
BWK) ⇒ page 121

nform
ercia
Removing and installing sump ⇒ page 124 .

m
a
com
ti
Removing and installing oil pump ⇒ page 126 .
on in
r
te o
thi
Checking oil pressure and oil pressure switch ⇒ page 128
s
iva
do
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1.1 Engine oil, oil capacities, engine oil

rp
cum
fo
en
g
specification (engine codes BLG, BMY)

n
t.
yi Co
Cop py
t. rig
gh
Oil capacities
ht
pyri by
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by
With oil filter 3.6 l
cted agen
Prote AG.
Engine oil specifications

⇒ Maintenance ; Booklet 38
Changing engine oil: ⇒ Maintenance ; Booklet 38 “Engine oil:
Drain or extract”.
1.2 Engine oil, oil capacities, engine oil

specification (engine code BWK)
Oil capacities
With oil filter 4.0 l
Engine oil specifications
⇒ Maintenance ; Booklet 24.1
Changing engine oil: ⇒ Maintenance ; Booklet 24.1 “Engine oil:
drain or extract”
1. Removing and installing parts of lubrication system 121

1 - Oil dipstick
AG. Volkswagen AG d
❑ The oil level must not ksw
be
agen oes
not
l
above the max. by mark!
Vo gu
ara
ed
❑ Markingsh⇒ orispage nte
eo
124 . s aut ra
c
s
2 - Engine oil cooler
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nl
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itte
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Note
erm
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ility
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♦ To remove:
, is n
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hole
♦ Drain coolant ⇒ page 136 .
spec
es, in part or in w
♦ Remove coolant pipe ⇒ Item 4
t to the co
(page 122) .
♦ Remove engine oil cooler.
rrectness of i
♦ Install in reverse order of re‐
l purpos
moval.
3 - O-ring
nform
ercia
❑ Renew
satelettronica
m
at
om
io
4 - Coolant pipe
n
c
in t
or
his
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❑ For oil cooler.

at
do
riv
❑ Specified torque, brack‐

p
cum
or
et to crankcase: 20 Nm.
f
en
ng
t.
yi Co
op
5 - 8 Nm C py
ht. rig
rig ht
by
6 - Sealing cover copy Vo
by lksw
cted agen
❑ Renew seal if damaged. Prote AG.
7 - Seal
8 - Oil filter cover, 25 Nm
❑ With bypass valve
opening pressure: 2.50 bar.
❑ With non-return valve.
9 - Filter element
10 - Valve
11 - Valve timing housing
❑ Install with sealant D 176 501 A1.
❑ Removing and installing valve timing housing (Golf, Golf Plus) ⇒ page 40 .
❑ Removing and installing valve timing housing (Touran, Tiguan) ⇒ page 44
❑ When installing, install two -M6x80- studs in camshaft housing and cylinder block as guides.
❑ To guide valve timing housing, secure oil sump in position with two bolts.
12 - 10 Nm
13 - Securing bolt
❑ Renew
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Secure pulley against turning with counterhold 3415.
14 - Pulley
122 Rep. gr.17 - Lubrication

❑ Contact surfaces of pulley must be free of oil and grease.
❑ Removing and installing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
❑ Removing and installing poly V-belt (engine code BWK) ⇒ page 38 .
❑ Secure pulley against turning with counterhold -3415- .
15 - Seal
16 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.
17 - Seal
AG. Volkswagen AG d
18 - Sprocket agen oes
olksw not
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❑ Removing and installing ⇒ page 94 d by ara
ise nte
r
❑ For oil pump drive. aut
ho eo
ra
ss c
19 - 20 Nm + 1/4 turn (90°) further
ce
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nl
pt
du
an
❑ Renew
itte
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satelettronica
erm
ab
20 - Sprocket
ility
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wit
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❑ For oil pump.
hole
spec
❑ Lock with counterhold -T10172- .
es, in part or in w
t to the co
21 - Drive chain
rrectness of i
❑ For oil pump.
l purpos
❑ Before removing, mark direction of rotation (installation position).

22 - 10 Nm
nf
ercia
o
23 - Oil level and oil temperature sender - G266-
rm
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❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
thi
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24 - Oil drain plug, 30 Nm
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❑ With captive seal
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❑ Renew Cop py
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25 - 13 Nm p by
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❑ Loosen and tighten flywheel end bolts only with Allen key, long reach 5 mm -T10058- .
cted agen
Prote AG.
26 - 40 Nm
27 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 600 A1
28 - 14 Nm + 1/4 turn (90°) further
29 - Oil pump
Caution
The oil supply line must
be renewed on the tur‐
bocharger if a new oil

pump or oil suction pipe

is fitted.
❑ with oil suction pipe

❑ Specified torque oil suction pipe: 9 Nm
30 - 5 Nm
31 - Oil separator
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched zone: engine oil can be added
c - Area from min. mark up to hatched field: top up, max. 0.5 l of
engine oil!
satelettronica
1.4 Removing and installing sump
AG. Volkswagen AG d
agen oes
Special tools and workshop equipment
Vol
ksw required not
gu
y
db ara
♦ Insert tool - T10058-orise nte
eo
th
s au ra
c
s
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le
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pt
an
d
itte
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rm
ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i

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nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.
♦ Hand drill with plastic brush
♦ Scraper
♦ Safety glasses
♦ Silicone sealant D 176 600 A1
Removing


– Disconnect front exhaust pipe from catalytic converter ⇒ page
330 .
– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.

– On the gearbox side, two screws may not be immediately ac‐
cessible. If the screw heads cannot be reached with a bit -
T10058- , turn the crankshaft in the engine direction until the
satelettronica
screws are accessible. The flywheel is provided with recesses.
Remove sump. Loosen sump with light blows of a rubber-
headed hammer if necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.

an electric drill with plastic brush attachment (wear eye pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing agen
AG. Volkswagen AG d
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Note utho eo
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♦ Check the expiry date of the sealant.
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pt
du
an
itte
♦ The sump must be installed within 5 minutes of applying sili‐

y li
erm
ab
cone sealing compound.

ility
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♦ Sump can be positioned more easily and with greater security

wit
, is n
h re
if M6 studs are inserted as guides into the cylinder block flange

hole
at two positions.
spec
es, in part or in w
t to the co
– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

nozzle).
rrectness of i
– Apply silicone sealing compound, as shown, to clean sealing

l purpos
surface on sump. Sealant bead must be:

♦ 2 to 3 mm thick
nf
ercia
♦ Run bead along inner side of bolt holes -arrows-.

rm
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atio
om
n in
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Note
thi
te
sd
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Cop py
t. rig
gh ht
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125
cop Vo
by lksw
Prote
cted AG. 1. Removing and installing parts of lubrication system
agen
The sealing compound bead cannot be thicker, or excessive seal‐

ing compound will enter the sump and may block the oil suction
pipe strainer.
AG. Volkswagen AG d
agen oes
lksw n t
– Install sump immediately byV
o and tighten all sump bolts olightly.
gu
ara
ed
is nte
– Tighten oil sumput
h bolts to 13 Nm.
or eo
a ra
s c
Specified torque
s for oil pan securing bolts to gearbox: 40 Nm
ce
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nl
pt
du
an
itte
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erm
Note
ab
ility
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Let sealing compound dry for approx. 30 minutes after installing
h re
oil sump. Only then fill with engine oil.
hole
spec
es, in part or in w
t to the co
1.5 Removing and installing oil pump
rrectness of i
Caution
l purpos
The oil supply line must be renewed on the turbocharger if a
satelettronica
new oil pump or oil suction pipe is fitted.
nform
mercia
at
om
io
n
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Hold oil pump sprocket with counterhold - T10172- .
– Loosen sprocket securing bolt.
Note
Do not remove bolt completely.

– Press chain tensioner in direction of arrow with a screwdriver.

– Remove sprocket securing bolt.
– Take sprocket off oil pump and out of chain.
– Loosen oil pump securing bolts -arrows- and remove them.

– Remove oil pump from cylinder block.
Installing
Caution
The oil supply line must be renewed on the turbocharger if a
satelettronica
new oil pump or oil suction pipe is fitted.
– Install oil pump and tighten securing bolts to 14 Nm + 1/4 turn

(90°) further.
Specified torque oil suction pipe: 9 Nm
– Press chain tensioner in direction of arrow with a screwdriver.

– Insert sprocket in chain and fit sprocket onto oil pump shaft.
AG. Volkswagen AG d
agen oes
olksw not
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an
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ility
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hole
spec
– Observe installation position of sprocket on oil pump shaft

es, in part or in w
-arrow-.
t to the co
– Fit sprocket securing bolt.

rrectness of i
– Hold sprocket with counterhold - T10172- .

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Apply torque wrench (5…50 Nm) - V.A.G. 1331- as shown in

illustration.
– Tighten securing bolt to 20 Nm +1/4 turn (90°) further.
1.6 Checking oil pressure and oil pressure switch

equipment required
satelettronica
lkswage es n
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byV ua
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ir se tee
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ss
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nl
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itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
♦ Oil pressure tester - V.A.G 1342-

do
priv
cum
or
♦ Voltage tester - V.A.G 1527B-

f
en
ng
t.
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op
♦ Adapter set - V.A.G 1594C-
C py
t. rig
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♦ 10 mm jointed spanner - T40175- cop Vo
by lksw
cted agen
Prote AG.

Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test sequence
The oil pressure switch is located on the gearbox side beneath
the two camshaft covers.
– Pull connector off oil pressure switch - F1- -arrow-.
satelettronica
– Remove oil pressure switch - F1- using hinged lever, 24 mm -
T40175- and screw into oil pressure tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- .
olkswagen AG
en AG. V
– If LED lights up, renew oil pressure switch
olks -F1- .
wag does
not
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db ara
If LED does not light up: rise nte
tho eo
– Start engine and increasessspeed slowly. At au 0.3 to 0.7 bar the
ra
c
LED must light up; otherwise renew oil pressure switch.
ce
e
nl
pt
du
an
– Increase engine speed further. At 2000 rpm and an oil tem‐

itte
y li
perature of 80 °C; the oil pressure should be at least 2.0 bar.

erm
ab
ility
ot p
At higher engine speeds, the oil pressure must not exceed 7.0
wit
, is n
bar.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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ng
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

19 – Cooling
1 Removing and installing parts of cool‐
ing system
Caution
♦ Observe the following points during all installation work, in

particular in the engine compartment, due to the space
limitations:
sitions.
satelettronica
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips. wage
e s no
ks
Vol t gu
♦ Hose clip pliers - VAS 6340- or spring-type clip
ed pliers - VAS
by ara
5024A- are recommended for use in installing
horis spring-type nte
eo
clips. ut ra
sa s c
ce
le
♦ When installing coolant hoses, route stress-free so that they

un
pt
do not come into contact with other components (observe
an
d
itte
y li
markings on coolant connection and hose).
erm
ab
ility
ot p
wit
Test for leaks in cooling system using cooling system tester -

is n
h re
V.A.G 1274 B- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .

ole,
spec
Assembly overview - parts of cooling system, body side (engine

t to the co
codes BLG, BMY) ⇒ page 131 .

Assembly overview - parts of cooling system, body side (engine
code BWK) ⇒ page 132
rrectne
Assembly overview - parts of cooling system, engine side ⇒ page

133 .
ss o
cial p
Coolant hose schematic diagram (engine codes BLG, BMY) ⇒

inform
page 135 .
mer
atio
m
Coolant hose schematic diagram (engine code BWK) ⇒ page

o
n
c
135 .
i
or
n thi
te
sd
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Draining and filling with coolant ⇒ page 136 .

iv
o
pr
cum
r
fo
Checking cooling system for leaks ⇒ page 140 .

en
ng
t.
yi Co
op
Removing and installing radiator fan - V7- and radiator fan 2 - C py
t. rig
V177- (engine codes BLG, BMY) ⇒ page 142 .
gh ht
pyri by
Vo
co lksw
by
Removing and installing radiator (engine codes BLG, BMY) ⇒ cted agen
Prote AG.
page 142 .
Removing and installing radiator and radiator fan - V7- (engine
code BWK) ⇒ page 144 .
Removing and installing coolant pump pulley ⇒ page 151 .
130 Rep. gr.19 - Cooling

Removing and installing coolant pump ⇒ page 146 .

Removing and installing coolant circulation pump - V50- ⇒
page 155 .
1.1 Assembly overview - parts of cooling system, body side (engine codes BLG,
BMY) swa
gen AG
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1 - Radiator/cooler tho eo
au ra
❑ Removing and installing ss c
⇒ page 142
ce
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nl
pt
du
an
❑ After renewing, renew
itte
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entire coolant.
erm
ab
ility
ot p
2 - O-ring
wit
, is n
h re
hole
spec
3 - Upper coolant hose
es, in part or in w
t to the co
❑ To connection on cylin‐
der head.
❑ Connection diagram for
rrectness of i
satelettronica
coolant hoses ⇒ page
l purpos
135
4 - Expansion tank
nform
ercia
❑ Check cooling system

for leaks using cooling
m
at
om
i
system tester - V.A.G
on
c
1274 B- and adapter for
in t
or
his
e
cooling system tester -

at
do
riv
V.A.G 1274/8-
p
cum
for
en
g
5 - Connector
n
t.
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op py
6 - Sealing cover
. C rig
ht ht
rig by
py
❑ Check using cooling co Vo
by lksw
system tester - V.A.G
cted agen
Prote AG.
1274 B- and adapter for
V.A.G 1274/9-
❑ Pressure relief valve
must open at pressure
of 1.4 to 1.6 bar
7 - 5 Nm
8 - Plastic inserts
❑ For securing bolts.
9 - Bracket
10 - Cowling
11 - 5 Nm
12 - Radiator fan 2 - V177-
13 - Connector
14 - Radiator fan - V7-
❑ With radiator fan control unit - J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.
1. Removing and installing parts of cooling system 131

17 - Retaining clip
18 - Radiator outlet coolant temperature sender - G83-
19 - 5 Nm
1.2 Assembly overview - parts of cooling system, body side (engine code BWK)
1 - Radiator/cooler
⇒ page 144
❑ After renewing, renew n AG. Volkswagen AG do
swage es n
entire coolant. byV
olk ot g
ua
d ran
ir se
2 - O-ring tho tee
or
au ac
❑ Renew if damaged ss
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nl
3 - Union
pt
du
an
itte
y li
❑ To remove, pull out re‐
erm
ab
taining clip.
ility
ot p
satelettronica
wit
, is n
4 - Spring-type clip
h re
hole
❑ Remove and install with
spec
hose clip pliers - VAS
es, in part or in w
t to the co
6340- .
5 - Coolant hose
rrectness of i
l purpos
135
6 - Upper coolant hose nform
ercia
❑ To connection on cylin‐
m
der head.
at
om
ion

c
in t
or

his
ate
135
do
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or
7 - Expansion tank
f
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ng
t.
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❑ Check cooling system . Cop py
for leaks using cooling
t rig
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system tester - V.A.G cop Vo
by lksw
1274 B- and adapter for cted agen
Prote AG.
V.A.G 1274/8-
8 - Connector
9 - Sealing cover
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
❑ Pressure relief valve must open at pressure of 1.4 to 1.6 bar
10 - 5 Nm
11 - Plastic inserts
❑ For securing bolts.
12 - Bracket
13 - 5 Nm
14 - Cowling with radiator fan - V7-
❑ With radiator fan control unit - J293- .

. Volkswagen AG
gen AG doe
swa
Golf 2004 ➤y ,VGolf Plus 2005 ➤ , Tiguan s2008
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ed
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Note
ce
le
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pt
an
d
itte
The radiator fan - V7- and the cowl‐
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rm
ab
ing may only be renewed complete.
pe
ility
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wit
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hole
WARNING
spec
es, in part or in w
Heat shields must be in‐
t to the co
stalled to prevent dam‐
age to radiator fan due to
heat radiated by exhaust
rrectness of i
system.
l purpos
❑ Specified torque for heat shields: 3 Nm.
nform
ercia
15 - Bracket
m
❑ For connector.
a
com
tion in
16 - Connector
r
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thi
s
iva
17 - Retaining clip
do
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rp
cum
fo
satelettronica
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ng
t.
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❑ To connection for thermostat. Cop py
ht. rig
❑ Connection diagram for coolant hoses ⇒ page 135
rig ht
py by
co Vo
by lksw
cted
19 - Hose guide
agen
Prote AG.
20 - Radiator outlet coolant temperature sender - G83-

❑ To connection for thermostat.
❑ Connection diagram for coolant hoses ⇒ page 135
22 - Union
❑ To remove, pull out retaining clip.
1.3 Assembly overview - parts of cooling

system, engine side
Thermostat side

1 - Union
2 - O-ring
❑ Renew
3 - Compression spring
4 - Plunger
❑ Do not cant when in‐
stalling wage
es n
olks ot g
5 - Thermostat 2 byV ua
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ir se tee
❑ Starts to open at 96 °C utho
or
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ss
6 - Radiator outlet coolant -
ce
le
un
G62-
pt
an
d
itte
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❑ Before removing, re‐
erm
ab
lease pressure in cool‐
ility
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ing system if necessary.
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7 - Retaining clip
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spec
❑ Check for firm seating
t to the co
8 - Thermostat housing
satelettronica
rrectne
9 - Seal
❑ Renew
ss o
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10 - Thermostat 1
f inform
❑ Starts to open at 80 °C
mer
atio
m
11 - To expansion tank
o
n
c
i
or
n
❑ Coolant hose schematic
thi
te
diagram (engine codes

sd
iva
o
r
BLG, BMY) ⇒ page

p
cum
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fo
135 .
en
ng
t.
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❑ Coolant hose schematic . Cop py
diagram (engine code
t rig
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BWK) ⇒ page 135 . cop Vo
by lksw
cted agen
Prote
12 - Union
AG.
13 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 134) .
❑ To remove, remove supercharger ⇒ page 255 .
❑ Coolant hose schematic diagram (engine codes BLG, BMY) ⇒ page 135 .
❑ Coolant hose schematic diagram (engine code BWK) ⇒ page 135 .
14 - Coolant pipe
❑ To remove, remove thermostat housing ⇒ Item 8 (page 134) .
❑ To remove, remove supercharger ⇒ page 255 .
15 - 5 Nm
16 - From bottom of radiator.
17 - To top of radiator

1.4 Coolant hose schematic diagram (engine codes BLG, BMY)
1 - Expansion tank
AG. Volkswagen AG d
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2 - Intake manifold olksw not
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3 - Heat exchanger for heater rise nte
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4 - Thermostat housing ss c
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6 - Radiator/cooler
erm
ab
ility
7 - Coolant circulation pump - ot p
wit
, is n
V50-
h re
hole
spec
es, in part or in w
⇒ page 155
t to the co
rrectness of i
⇒ page 238
l purpos
9 - Cylinder head/cylinder
satelettronica
block
nform
ercia
❑ If renewed, refill system

with fresh coolant.
m
at
om
io
10 - Auxiliary heater
n
c
in t
or
❑ Optional equipment
his
ate
do
priv
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for
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ng
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Cop py
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Prote AG.
1.5 Coolant hose schematic diagram (engine code BWK)

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plusut 2005 ➤ , Tiguan 2008 ➤ , Touran 2003 ➤ e or
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1 - Expansion tank
d
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ab
2 - Intake manifold
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3 - Heat exchanger for heater
is n
h re
ole,
4 - Thermostat housing
spec
t to the co
6 - Radiator/cooler
rrectne
7 - Coolant circulation pump -
V50-
s
s o
⇒ page 155
cial p
f inform
mer
atio
m

o
n
c
⇒ page 238
i
or
n thi
te
sd
a
9 - Cylinder head/cylinder
iv
o
pr
c
block
um
r
fo
en
ng
❑ If renewed, refill system

t.
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op
with fresh coolant. C py
satelettronica
t. rig
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10 - Auxiliary heater
p by
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cted
❑ Optional equipment
agen
Prote AG.
1.6 Draining and adding coolant

olks
wage es n
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equipment requiredd by V ua
ran
e
ris tee
tho or
au 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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
satelettronica
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Refractometer - T10007 A-
♦ Coolant system charge unit - VAS 6096-
Draining
WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Open filler cap on coolant expansion tank.

Engine codes BLG, BMY

Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan agen 2008 ➤ , Touran
AG. Volkswagen AG d 2003 ➤
oes
ksw
by
V (1.4 l, EA 111, turbocharger,otsupercharger)
ol n
gu - Edition 08.2017
ara
ed nte
oris
– Pull off retaining clip -arrow-aand
ut
h remove coolant hose from e or
ac
radiator. ss
ce
le
un
pt
Engine code BWK
an
d
itte
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erm
ab
ility
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is n
h re
ole,
spec
t to the co
rrectne
– Detach spring-type clip and pull off coolant hose -2-.
ss o
Disregard item -1-.
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
Please observe disposal instructions!
te
sd
iva
o
r
satelettronica
p
cum
r
fo
Filling
en
ng
t.
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Cop py
t. rig
Caution
gh ht
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Vo
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by c lksw
cted agen
Use only distilled water for mixing coolant additives. The use
Prote AG.
of distilled water ensures optimum protection against corro‐

sion.
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been spec‐
ified by Volkswagen. Distilled water fulfils all requirements.
Therefore, always use only distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Use ONLY refractometer - T10007A- for determining current
anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐

ever, be increased only to a maximum of -48°C. Otherwise,

the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished
olks
wcoolant
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additives. db
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♦ The temperature read off the refractometer uth - T10007A- corre‐
o
or
sponds the »ice flocculation point«. Flakes
ss
a
of ice may start ac
forming in the coolant at this temperature.
ce
le
un
pt
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d
♦ Never reuse old coolant.
itte
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rm
ab
♦ Use only a water/coolant additive mixture as a slip agent for
pe
ility
ot
coolant hoses.
wit
, is n
h re
hole
spec
Recommended mixing ratios (use only distilled water for mixing):
es, in part or in w
t to the co
Frost Amount of anti- Coolant ad‐ Distilled wa‐
protection to freeze ditive 11) ter 11)
rrectness of i
-25°C 40% 2.25 l 3.35 l
-36°C 50% 2.8 l 2.8 l
satelettronica
l purpos
11) The quantity of coolant can vary depending upon vehicle equipment.
nform
ercia
– Press connection against radiator and slide retaining clip

m
-arrow- into groove.
a
com
tion in
– Install engine splash protection.
r
te o
thi
s
iva
With cooling system charge unit - VAS 6096-
do
r
rp
cum
fo
– Fill coolant circuit using cooling system charge unit -
en
ng
t.
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VAS 6096- ⇒ Operating instructions for cooling system
Co
op py
charge unit VAS 6096 .
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ht ht
rig by
py
Without cooling system charge unit - VAS 6096-
co Vo
by lksw
cted agen
Prote AG.
– Fill with coolant up to max. mark on expansion tank.

With or without cooling system charge unit - VAS 6096-
– Fit expansion tank cap.
– Turn off heater controls.
Vehicles with no auxiliary heater
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Run engine until radiator fan - V7- cuts in.
Vehicles with auxiliary heater
Caution
Do not switch auxiliary heater on until the cooling circuit has

been filled as described below.

– Connect vehicle diagnostic tester as follows:

– Push diagnosis cable connector onto diagnosis connection in
driver footwell.
– Start engine and maintain an engine speed of about 2,000 rpm
for about 3 minutes.
– Press buttons on display for “Vehicle self-diagnosis”, “18 -
Auxiliary/supplementary heater” and “03 - Final control diag‐
nosis” one after the other.
– Press right arrow button on display up to final control diagnosis
for heater coolant shut-off valve - N279- .
– Initiate final control diagnosis for heater coolant shut-off valve
- N279- . Continue to maintain engine speed of approx. 2,000
rpm for about 1 minute.
– Run engine until radiator fan - V7- cuts in.
WARNING n AG. Volkswagen AG do

lk swage es n
o ot g
satelettronica
yV
Hot steam may escape when expansion d b tank is opened. Wear ua
ran
ir se
protective goggles and clothingthto
o avoid eye injuries and scald‐ tee
or
ing. Cover cap with a cloth andau carefully open. ac
ss
ce
e
nl
pt
du
an
itte
– Check coolant level and top up as needed. The coolant level
y li
erm
ab
must be at the max. marking when the engine is at normal
ility
ot p
operating temperature, and between the min. and max. mark‐
wit
, is n
ings when the engine is cold.
h re
hole
1.7 Checking cooling system for leaks spec

es, in part or in w
t to the co
♦ Cooling system tester - V.A.G 1274 B-
rrectness of i
♦ Adapter for cooling system tester - V.A.G 1274/8-

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

♦ Adapter for cooling system tester - V.A.G 1274/9-
AG. Volkswagen AG d
agen oes
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y V gu
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au ra
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nl
pt
du
an
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ab
ility
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wit
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• Engine at operating temperature.
h re
hole
spec
Test sequence
es, in part or in w
t to the co
WARNING
rrectness of i
satelettronica
Hot steam may escape when expansion tank is opened. Place
cloth over cap and open with caution.
l purpos
nf
ercia
– Open cap on coolant expansion tank.
orm
m
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
atio
m
expansion tank.
o
n in
or c
thi
e
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

t
sd
iva
system tester - V.A.G 1274/8- .
o
r
rp
cu
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f
en
– Join connection piece - V.A.G 1274 B/1- to cooling system
ng
t.
yi Co
tester - V.A.G 1274 B- using connecting hose supplied. t. Cop py
rig
gh ht
– Use hand pump on tester to create a pressure of about 1.0 bar. pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.
If the pressure drops:

– Find leaks and rectify.
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
The pressure relief valve must still remain closed.
If the pressure relief valve opens prematurely:

– Renew sealing cap.

– Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
– Renew sealing cap.
1.8 Removing and installing AG. Volkradiator

swagen AG fan -
agen does
V7- and radiator
by Vol
ksw
fan 2 - V177- (engine
not
gu
ara
codes BLG, BMY)
d
rise nte
tho e or
au ac
Removing radiator sfan
s
ce
e
nl
pt
– Remove engine cover.
du
an
itte
y li
– Remove upper securing bolts of cowling -arrows-.
erm
ab
ility
ot p
– Remove noise insulation ⇒ General body repairs, exterior;
wit
, is n
Rep. gr. 50 ; Body - front; Noise insulation .
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
– Separate connector -1- and unscrew lower cowling securing

at
om
io
bolts -arrows-.
n
c
in t
or
his
– Remove cowling downwards.

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.
– Separate electrical connector -1- and free wiring.

– Unscrew nuts -arrows- and remove fan.
Installing radiator fan
note the following:
Specified torques:
Component Nm
Radiator fan to cowling 10
Cowling to radiator 5
1.9 Removing and installing radiator (engine codes BLG, BMY)


equipment required
satelettronica
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

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

sition .
rrectness of i

l purpos
– Pull coolant hoses off radiator.

nform
ercia

m
– Remove radiator securing bolts and remove radiator with fan

com
tion in
downwards.
r
te o
thi
s
iva
do
r
rp
Note
um
fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

– Unbolt condenser from radiator and secure to lock carrier.

Installing
. Volkswagen AG
a gen AG does
Vol
ksw not
gu
note the following: e d by ara
nte
ris
ho eo
Filling with new coolant ⇒ page 136 . aut ra
ss c
– Electrical connections and routing ⇒ Current flow diagrams,
ce
e
nl
pt
Electrical fault finding and Fitting locations.
du
an
itte
y li
erm
1.10 Removing and installing radiator and radiator fan - V7- (engine code BWK)
ab
ility
ot p
wit
, is n
h re
hole
spec
equipment required
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing

. Volkswage
Golf 2004 wage➤ , Golf Plus 2005
n AG n AG d
o➤
es n, Tiguan 2008 ➤ , Touran 2003 ➤
olks ot g
d by V (1.4 l, EA 111, turbocharger, supercharger)
ua
r
- Edition 08.2017
e an
ris tee
ho
– Remove front right wheel auhousing liner ⇒ General body re‐
t or
ac
ss
ce
le
un
pt
an
d
itte
y li
– Remove bracket -1- by unscrewing securing bolts -arrows-.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Push securing clip at charge air cooler in direction of -arrow-
atio
m
and pull hose -arrow- off.

o
n
c
i
or
n
– Also remove second hose from charge air cooler.
thi
te
sd
iva
o
pr
satelettronica
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Disconnect connector -1-.

– Release retaining clip and pull connection -arrow- off radiator.

– Also pull off connection at bottom of radiator.
sition .

– Unscrew securing bolts -arrows- and remove cowling upwards

together with radiator fan - V7- .
Note
The radiator fan - V7- and the cowling may only be renewed com‐
plete.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
– Remove securing bolt -arrow-. ss
a ac
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolts -arrows- and remove radiator downwards.

Installing
nf
ercia
orm
m
atio
m
note the following:

o
n in
or c
thi
Filling with new coolant ⇒ page 136 .
te
sd
iva
o
r
Specified torques:
rp
cu
o
m
f
en
ng
t.
yi
Component Nm
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Radiator to charge air cooler 5
by lksw
cted agen
Prote AG.
1.11 Removing and installing coolant pump
Note
Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.


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
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ 16 mm open-end spanner - T10241- (not shown)
♦ Bit - T10451- (not shown)
Removing

– Pull off hose -1- from pressure pipe.

– Unscrew securing bolts -2- from pressure pipe and remove
pressure pipe.
– Unscrew hose clip -1- on charge air pipe.

– Open hose clip -2- and pull out hose.
– Unscrew securing bolt for charge air pipe -3-.
satelettronica
– To do so, remove bolts -arrows-. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove bracket -1-. ed by ara
nte
ris
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
– Unscrew bolts -arrows- and remove charge pressure sender -
G31- -1-. rrectne
ss
– Removing poly V-belt (engine codes BLG, BMY) ⇒ page 36 .

o
cial p
f in
– Removing poly V-belt (engine code BWK) ⇒ page 38 .

form
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.


– Remove securing bolt -arrow- for charge air pipe -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
satelettronica
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Unscrew securing bolt for charge air pipe -arrow- and remove
hole
spec
charge air pipe -1- downwards.
es, in part or in w
t to the co
Tiguan
– Remove front exhaust pipe ⇒ page 334 .
rrectness of i
l purpos
Note
nform
The front exhaust pipe is only unbolted at the attaching points and
ercia
placed down on the subframe.

m
a
com
Only vehicles with auxiliary heater tion in

r
te o
thi
s
iva
– Remove coolant hoses for auxiliary heater.

do
r
rp
cum
fo

en
ng
t.
yi Co
Cop py
– Carefully press locking lugs on noise insulation housing for
t. rig
gh ht
yri by
supercharger -arrows- outwards. cop Vo
by lksw
cted agen
Prote
– Pull off front housing with noise insulation.
AG.

– Release tension from supercharger poly V-belt by swinging

tensioning element using open-end spanner, 16 mm -
T10241- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Unscrew securings abolts
u -arrows- for tensioning element and ac
remove tensioning element. s
ce
le
un
pt
– Tightly hold compressor shaft with a spanner -1-.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove securing bolt -2- for pulley and remove pulley and
supercharger poly V-belt -3-.
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen bolts for coolant pump with magnetic clutch for super‐
charger - N421- -arrows- with the bit - T10451- .
– Remove coolant pump with magnetic clutch for supercharger
- N421- from cylinder block.
Installing
Note
Coolant pump seal is bonded in position. If the seal is damaged,

the coolant pump must be renewed.

note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing bolts to 8 Nm.
– Place poly v-belt on the magnetic clutch for supercharger -
N421- .

– Bolt on supercharger pulley with poly-v-belt and new securing

bolt.
Specified torques:
Assembly overview - part I, belt drive ⇒ page 31 .
Assembly overview - supercharger ⇒ page 254
Assembly overview - charge air system ⇒ page 275
– Install poly V-belt (engine codes BLG, BMY) ⇒ page 36 .
– Install poly V-belt (engine code BWK) ⇒ page 38 .
– Add coolant ⇒ page 136 .
1.12 Removing and installing coolant pump pulley

equipment required
satelettronica
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
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rp
cu
o
m
f
en
ng
t.
yi Co
op
♦ Bit XZN 10 - T10154-
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
Removing


Engine code BWK
– Pull retaining clip in direction of -arrow- and pull charge air

hose -1- out of charge air pipe.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Unscrew securing bolt for charge air pipe -arrow-.
ss a 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
– Release vacuum hose from vacuum reservoir -arrow- and pull

off.
nf
ercia
rm
m
rection of -arrow-.
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.


rection of -arrow-.
satelettronica
AG. Volkswagen AG d
agen oes
– Pull hose -1- from pressure
Vol
ksw pipe. not
gu
by ara
ed
– Unscrew securing oris bolts -2- from pressure pipe and remove nte
eo
pressure pipe.au
th ra
ss c
– Unscrew hose clip -1- at charge air pipe.
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
– Open hose clip -2- and pull hose out.

rrectness of i
– Unscrew securing bolt for charge air pipe -3- and pull connec‐
l purpos
tor off charge air pressure sender - G31- with intake air tem‐
perature sender 2 - G299- .
nform
mercia
Note
at
om
ion
c
in t
or
Charge air pressure sender - G31- with intake air temperature

his
te
sender 2 - G299- is installed on rear of charge air pipe.

a
do
priv
cum
for
en
g

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

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran ised b 2003 ➤ ara
nte
r
ut
ho supercharger) - Edition 08.2017 e or
a ac
ss
– Loosen securing bolts -1- for coolant pump pulley.
ce
le
un
pt
an
d
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
As the poly V-belt is still tensioned, the pulley securing bolts
h re
ole,
must not yet be removed.
spec
t to the co
rrectne
ss o
cial p
f
– Unscrew securing bolts -1- and pull pulley from coolant pump.
inform
Installing mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
satelettronica
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Position pulley on coolant pump and tighten securing bolts

-1- hand-tight.
– Tighten securing bolts to 24 Nm.
Further installation is carried out in reverse order of removal.
When installing, note the following:
Specified torques:
Assembly overview - part I, intake manifold ⇒ page 288 .
Note



satelettronica
1.13 Removing and installing coolant circulation pump - V50-
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
155
co Vo
by lksw
cted 1. Removing and installing parts of cooling system
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008ris➤ , Touran 2003 ➤
ed
nte
o eo
4-cylinder direct-injection engine (1.4 l, EAa111,
ut
h
turbocharger, supercharger) - Edition 08.2017 ra
ss c
ce
e
nl
pt
du
an
equipment required
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
satelettronica
Cop py
ht. rig
rig ht
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Removing
Engine code BWK

– Remove spring-type clips -arrows- and pull coolant hoses off.

– Pull connector -1- off and remove securing bolt -2-.
– Remove coolant circulation pump - V50- .
Installing
note the following:
Specified torque for securing bolt: 10 Nm.
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Releasing pressure in high-pressure area ⇒ page 158 .
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1.1 Safety regulations for working on fuel
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WARNING
Fuel system is under pressure! Wear eye protection and gloves

to avoid injuries and skin contact. Wrap a cloth around the
connection before loosening hose connections. Then release
pressure by carefully pulling hose off connection.
♦ Even before work starts, the extraction hose of a fume extrac‐

tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.2 Releasing pressure in high-pressure

area
WARNING
The injection system consists of a high-pressure section (max‐

imum approx. 120 bar) and a low-pressure section (approx.
6 bar).
Prior to opening the high-pressure section, e.g. when removing
the high-pressure pump, fuel rail, injectors, a fuel line, or the
fuel pressure sender - G247- , the fuel pressure in the high-
158 Rep. gr.20 - Fuel supply system

pressure area must be reduced to a residual pressure of ap‐

prox. 6 bar. The appropriate procedure is described as follows.
– Pull electrical connector off fuel pressure regulating valve -

N276- -arrow-.
– Run engine at idling speed for approx. 10 seconds.
Note
♦ When the engine is idling and the electrical connector is pulled

off the fuel pressure regulating valve - N276- , the pressure in
the high-pressure system will drop to approx. 6 bar.
♦ Once the high-pressure in the high-pressure area is reduced,
open the system immediately as the pressure will rise again
due to warming.
– Switch off ignition.
WARNING
satelettronica
The fuel lines are pressurized! Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Before opening the high-pressure section, wrap a cloth around
the connection.
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– Wrap a clean cloth around the Vol
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not
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– After completing work,
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1. Safety precautions 159

2 Fuel tank
158 .
Observe rules for cleanliness ⇒ page 180 .
Assembly overview - fuel tank (Golf, Golf Plus) ⇒ page 160
Draining fuel tank (Golf, Golf Plus) ⇒ page 161
Removing and installing fuel tank (Golf, Golf Plus) ⇒ page
164
Assembly overview - fuel tank (Touran) ⇒ page 165
Draining fuel tank (Touran) ⇒ page 167
Removing and installing fuel tank (Touran) ⇒ page 170 .
Assembly overview - fuel tank (Tiguan) ⇒ page 171 .
Draining fuel tank (Tiguan) ⇒ page 173
Removing and installing fuel tank (Tiguan) ⇒ page 176 .
satelettronica
2.1 Fuel tank - assembly overview (Golf, Golf Plus)
1 - Sealing cover
2 - Securing bolt
3 - Earth connection
❑ Ensure firm seating
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7 - 25 Nm
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❑ Renew
8 - Clamping washer
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9 - Securing strap
❑ Observe installation po‐
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13 - Breather line
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❑ Clipped onto side of fuel tank.
14 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
15 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 184 .
❑ Note installation position on fuel tank ⇒ page 161
❑ With fuel gauge sender - G-
❑ Removing and installing fuel gauge sender - G- ⇒ page 183
❑ Clean strainer if soiled
16 - Locking ring 110 Nm
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19 - Tank flap unit

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❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
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Installation position of fuel delivery unit

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Marking -3- on sender points opposite to direction of travel.

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2.2 Draining fuel tank (Golf, Golf Plus)

2. Fuel tank 161

♦ Fuel extraction unit - VAS 5190-
♦ Special wrench - T10202-
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Emptying fuel tank if it is less than 3/4 full ⇒ page 163
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2.2.1 Emptying fuel tank if it is more than 3/4
full
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– Drain fuel tank as much as possible through fuel filler neck.

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♦ If work must be performed on fuel pump or fuel tank sender,

proceed as follows:
2.2.2 Emptying fuel tank if it is less than 3/4 full

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
– Remove cover from fuel delivery unit.
WARNING
Fuel supply line is pressurised. Wear protective goggles and

Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.
2. Fuel tank 163

– Open locking ring using key - T10202- .

– Raise fuel delivery unit.
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2.3 Removing and installing fuel tank (Golf,
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Golf Plus)
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Removing
theft code.
– With the ignition switched off, disconnect battery earth strap.
– Unscrew securing bolts and remove tank flap unit.
– Drain fuel tank and clean fuel filler neck and surrounding area.

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– Disconnect all rear exhaust system retainers from body. Then
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– Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
Press in securing ring to release the fuel lines.
– Unscrew securing strap and securing bolts. When doing this,

support fuel tank with engine and gearbox jack -
V.A.G 1383 A- .
– Lower fuel tank.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
♦ Install breather lines and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ After installing fuel tank, check that the supply, return and
breather lines are still clipped onto the fuel tank.
2.4 Assembly overview - fuel tank (Touran)
2. Fuel tank 165

1 - Sealing cover
2 - Securing bolt
3 - Tank flap unit
⇒ General body re‐
pairs, exterior; Rep. gr.
55 ; Tank flap unit; Re‐
moving and installing fu‐
el tank flap unit .
5 - 11 Nm wage
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10 - Supply line
❑ black
11 - Fuel filter
❑ Installation position: arrow indicates direction of flow.
12 - Breather line
13 - Activated charcoal filter
❑ Location: on fuel tank.
14 - Breather line

❑ With fuel gauge sender - G- ⇒ page 183
❑ Checking fuel pump
❑ Note installation position on fuel tank ⇒ page 167
❑ Removing and installing fuel gauge sender - G- ⇒ page 183
❑ Following installation, adapt fuel pump control unit - J538- to engine control unit ⇒ Vehicle diagnostic
tester “Guided Function”
16 - Seal
17 - Union nut, 80 Nm
❑ Remove and install using union nut tool - 3217- .
❑ Position union nut tool - 3217- on the three rounded pins
18 - Supply line
❑ black
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19 - Return line
❑ blue
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2.5 Draining fuel tank (Touran)

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2. Fuel tank 167

♦ Key for union nut - 3217-
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Emptying fuel tank if it is less than 3/4 full ⇒ page 169
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– Remove filler cap from fuel tank filler neck. db
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proceed as follows:

WARNING

off connection.
Note
2. Fuel tank 169

– Open locking ring using union nut tool - 3217- .

– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 181 .
2.6 Removing and installing fuel tank

(Touran)
• The fuel tank must be filled no more than 1/2 way up.
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Removing
theft code.

– Fold rear seat bench forwards.
– Pull 5-pin connector -1- off flange.
– Unbolt filler neck from body -arrows-.

– Disconnect all rear exhaust system retainers from body. Then
support lowered exhaust system on body with wire.
satelettronica
WARNING
– Disconnect breather line -1- (white) and fuel line -2- (black) at
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♦ To secure the securing straps for the fuel tank, only bolts with
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♦ After installing fuel tank, check that the supply, return and
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2.7 Assembly overview - fuel tank (Tiguan)
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2. Fuel tank 171

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page 173
❑ With fuel gauge sender
- G-
fuel gauge sender - G-
⇒ page 212
7 - Supply line
❑ black
❑ Clipped onto side of fuel
tank.
8 - Fuel gauge sender 2 - G169-
❑ With suction-jet pump
9 - 3.5 Nm
10 - Bracket for fuel pump control unit - J538-
11 - Fuel pump control unit - J538-
12 - Seal
13 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
14 - 20 Nm + 1/4 turn (90°) further
❑ Renew

Note

15 - Securing strap
❑ Observe installation position
16 - 20 Nm + 1/4 turn (90°) further
❑ Renew
17 - Clamping washer
18 - Heat shield
19 - Breather line
20 - Breather line
satelettronica
21 - 8 Nm + 1/4 turn (90°) further
❑ Renew
22 - Tank flap unit
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit . olkswa AG. V gen AG
agen does
olksw not
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Installation position of flange for fuelthodelivery unit and fuel
ri gauge eo
sender 2 - G169- au ra
c
ss
ce
le
Fuel delivery unit -3-:

un
pt
an
d
itte
The lug -1- points in direction of travel.

y li
rm
ab
pe
ility
Fuel gauge sender 2 - G169- -2-:

ot
wit
, is n
The lug -1- points in direction of travel.

h re
hole
spec
es, in part or in w
t to the co
Note
The arrows on the locking rings may be disregarded.

rrectness of i
l purpos
2.8 Draining fuel tank (Tiguan)

nform
ercia

m
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com
tion in
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fo
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Cop py
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cted agen
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2. Fuel tank 173

AG. Volkswagen AG d
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olksw not
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rise nte
tho eo
au ra
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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
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Note safety precautions before beginning work ⇒ page 158 . do

priv
cum
or

f
en
ng
t.
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op py
Emptying fuel tank if it is less than 3/4 full ⇒ page 175 t. C rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
full
Caution

part of the body.
– At a distance of -a- = 1200 mm from the end of the extraction
hose, mark hose with insulating tape -arrow-.

– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
Note
-arrow-.
olkswagen AG
satelettronica
en AG. V
– Drain fuel tank as much as possible
olks through fuel filler neck. s not
wag doe
V gu
by ara
– Carefully pull out extraction
or
ishose.
ed nte
th eo
s au ra
c
s
ce
e
Note
nl
pt
du
an
itte
y li
erm
ab
ility
enough for the sender flange to be opened without danger.
ot p
wit
, is n
h re
hole

proceed as follows: spec
es, in part or in w
t to the co

rrectness of i

l purpos

nform
mercia
at
om
WARNING
ion
c
in t
or
his
e

at
do
riv

p
cum
or

f
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ng
t.
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op
off connection.
C py
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co lksw
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Prote
AG.
Note
2. Fuel tank 175


– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 181 .
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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aut ra
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nl
pt
du
an
2.9 Removing and installing fuel tank
itte
y li
erm
ab
(Tiguan)
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu

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ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
Removing
theft code.

ks wage es n
– Pull connector -1- and fuel line -2- off right flange Vol (in direction ot g
by ua
of travel). ris
ed ran
tee
tho or
s au ac
s
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
– Release connector -arrow- on fuel pump control unit - J538-
rrectness of i
using assembly tool - T10118- and pull it off.
l purpos
nform
mercia
a
com
tion in
satelettronica
r
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thi
s
iva
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t.
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Cop py
t. rig
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– Pull connector -1- off left flange (in direction of travel). p by
co Vo
by lksw
cted agen
Prote AG.

2. Fuel tank 177


– Remove rear exhaust system with centre and rear silencers.

– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 ; Removing and installing propshaft .
WARNING
satelettronica
lease pressure by carefully pullingnhose
AG. Vooff
lkswconnection.
agen AG
age does
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th
– Disconnect fuel auline -1- (black) and breather line -2- (white) at or ac
ss
connecting point.
ce
le
un
pt
– If an auxiliary heater is fitted, also separate fuel line -3-.

an
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
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hole

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

rrectness of i

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– Disconnect breather lines -1- from activated charcoal filter and

nform
ercia
fuel tank filler neck -3-.

m
– Unclip cable -2- from bracket.

com
tion in
r
– Remove tank flap and fuel tank filler neck cap.

te o
thi
s
iva
do
– Disconnect earth cable at fuel tank filler neck.

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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.

– Unbolt filler neck from body -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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un
pt
an
d
itte
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erm
ab
– Remove securing bolt -1-.
ility
ot p
wit
is n
– Unscrew securing strap and securing bolts -arrows-. When
h re
ole,
doing this, support fuel tank with engine and gearbox jack -
spec
V.A.G 1383 A- .
t to the co
Installing
– With the aid of a second mechanic, guide the filler neck in be‐
rrectne
tween rear axle and body. Then place fuel tank on engine and
satelettronica
gearbox jack - V.A.G 1383 A- .
ss o
cial p
f inform
mer
atio
m
– Raise fuel tank slowly up to installation position and secure it

o
n
c
i
in place.
or
n thi
te
sd
iva
o
pr
cum
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fo
Note
en
ng
t.
yi Co
Cop py
To secure the securing straps for the fuel tank, only bolts with
t. rig
gh ht
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loose washers must be used. If different bolts are used, the se‐
p by
o Vo
by c lksw
curing straps might twist during tightening. Prote
cted AG.
agen
Tighten new securing bolts for securing straps -arrows- and new
bolt -1- to 20 Nm + 1/4 turn (90°) further.
– Tighten securing bolts -arrows- for fuel tank filler neck to 8 Nm

+ 1/4 turn (90°) further.
Further installation is carried out in reverse order of removal. Dur‐
ing this procedure, observe the following:
♦ Check earth connection on fuel tank and body to filler neck.
♦ After installing fuel tank, check that supply and breather lines
are still clipped onto fuel tank.
2. Fuel tank 179

3 Removing and installing parts of fuel

supply system
Note
Volkswagen AG
♦ Hose connections are secured with either spring-type agor
en AG. does
ksw
clamp-type clips. by
Vol not
gu
ara
d
ise nte
♦ Always renew crimp-type clips with spring-type
tho
r clips. eo
au ra
c
♦ Fuel hoses on engine must be securedss with spring-type clips
ce
le
only. The use of crimp-type or screw-type clips is not permis‐
un
pt
an
sible.
d
itte
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erm
ab
♦ Hose clip pliers - VAS 6340- are recommended to install
ility
ot p
spring-type clips.
wit
is n
h re
ole,
spec
158 .
t to the co
satelettronica
Observe crash fuel shut-off ⇒ page 181 .
rrectne
Removing and installing fuel delivery unit (Golf, Golf Plus) ⇒ page
181 .
ss o
cial p
f
Removing and installing fuel gauge sender G (Golf, Golf Plus) ⇒
inform
page 183
mer
atio
m
Checking fuel pumps (Golf, Golf Plus) ⇒ page 184

o
n
c
i
or
n
Removing and installing fuel delivery unit (Touran) ⇒ page
thi
te
sd
195 .
iva
o
pr
cum
r
Removing and installing fuel gauge sender G (Touran) ⇒ page

fo
en
ng
197 .
t.
yi Co
Cop py
t. rig
Checking fuel pump (Touran) ⇒ page 198 . opyri
gh by
Vo
ht
c lksw
Removing and installing fuel delivery unit (Tiguan) ⇒ page
by
cted agen
Prote
209 .
AG.
Removing and installing fuel gauge sender G (Tiguan) ⇒ page

212 .
Removing and installing suction-jet pump (Tiguan) ⇒ page
212
Removing and installing fuel gauge sender 2 - G169- (Tiguan) ⇒
page 215 .
Checking fuel pump (Tiguan) ⇒ page 215 .
Removing and installing fuel pump control unit - J538- (Tiguan)
⇒ page 223
3.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.

♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
3.2 Crash fuel shut-off

Function
Crash fuel shut-off system reduces the risk of a vehicle burning
in event of a crash in that the fuel pump is switched off. The sys‐
tem also improves the starting characteristics of the engine. When
door is opened, the fuel pump is activated for 2 seconds to build
up pressure in the fuel system.
When opening fuel system:
Observe safety precautions ⇒ page 158 .
3.3 Removing and installing fuel delivery

unit (Golf, Golf Plus)
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt

du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Removing
rm
m
atio
m
Condition
o
n in
or c
• The fuel tank must be filled no more than 1/2 way up.
thi
te
sd
iva
o
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o
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f
Note
en
ng
t.
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Cop py
t. rig
If necessary, drain fuel tank using fuel extractor - VAS 5190- .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Removing and installing parts of fuel supply system 181

– First check whether a coded radio is fitted. nIfAso,

G. Voobtain
lkswageanti-
n AG d
theft code. olks wage oes
no
V t gu
by ara
– With the ignition switched off,risdisconnect
ed battery earth strap. nte
tho eo
– Fold rear bench seat forwards.
ss
au ra
c
ce
e
– Remove cover from fuel delivery unit -arrows-. nl
pt
du
an
itte
y li
– Remove cover -1- with fuel pump control unit - J538- -2- from
erm
ab
fuel delivery unit.
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
Fuel system is under pressure! Wear eye protection and gloves
t to the co
rrectness of i
l purpos
nf
ercia
or
– Pull off connector -arrow-.
m
m
atio
satelettronica
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull fuel lines -1- and -2- off the flange.
Note
♦ Press in securing ring to release the fuel lines.

♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using key - T10202- and raise flange slightly.
– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before

disposal.
♦ Observe disposal regulations!
Installing
– Renew seal.

– Insert seal for fuel delivery unit dry into opening of fuel tank.
– Coat inner side of seal with fuel.
– When inserting fuel delivery unit, ensure that fuel gauge
sender is not bent.
– Press sealing flange down against spring pressure, and move

sealing flange to installation position.
• Tab -2- on flange must be between lugs -1- and -3- on fuel
tank.
• -Arrow- points in direction of travel.
– Tighten sealing flange.
• Specified torque: 110 Nm
– Reconnect supply line-1- (black).

– Reconnect fuel return line -2- (blue or blue marking).
satelettronica
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
h re
ole,
spec
– Reconnect connector -arrow-.
t to the co
– Ensure push-fit couplings and electrical connectors are se‐
cured properly by pulling.
rrectne
Further assembly is performed in the reverse order of removal.
During this procedure, observe the following:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
♦ Observe installation position of fuel feed line to auxiliary heater

en
ng
t.
yi
⇒ Auxiliary heater; Rep. gr. 82 ; Fuel feed Thermo Top V .
Co
Cop py
t. rig
gh
♦ The -arrow- on the cover points forwards.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3.4 Removing and installing fuel gauge

sender G (Golf, Golf Plus)

Removing
– Remove fuel delivery unit ⇒ page 181 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
– If the sender cannot be released in this way, the retaining tabs
spec
-arrows- must also be pushed to the side slightly.
es, in part or in w
t to the co
– Note colour co-ordination of cables for reinstallation.
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Release electrical connectors -1 to 3- and pull them off. Then
r
rp
cum
bend back locking lugs of connectors.
fo
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
– Install fuel delivery unit ⇒ page 181 .
3.5 Checking fuel pumps (Golf, Golf Plus)
Note

After removing fuel delivery unit, check fuel tank for heavy soiling
and clean if necessary.

equipment required
satelettronica
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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♦ Pressure gauge - VAS 6550-

rm
ab
pe
ility
♦ Remote control - V.A.G 1348/3A-

ot
wit
, is n
h re
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-

hole
spec
♦ Multimeter - V.A.G 1715-

es, in part or in w
t to the co

rrectness of i
♦ Measuring container, capacity 2 litres

l purpos
3.5.1 Checking function and voltage supply

nform
ercia
Test conditions:
m
a
com
• Battery voltage at least 11.5 V.

tion in
r
te o
• Fuse for Fuel pump control unit - J538- OK.

thi
s
iva
do
• Fuel pump control unit - J538- OK.

r
rp
cum
fo
en
g
Test sequence
n
t.
yi Co
Cop py
ht. rig
rig ht
by
185
copy Vo
by lksw
cted 3. Removing and installing parts of fuel supply system
agen
Prote AG.
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
Function of fuel pump is checked using final controlodiagnosis.
ris
ed
nte
h eo
aut ra
s c
– Connect vehicle diagnostic tester as follows:s
ce
e
nl
pt
du
an
itte
y li
driver footwell.
erm
ab
ility
ot p
– Switch ignition on.
wit
, is n
h re
– Press buttons on display one after the other for Vehicle
hole
spec
self-diagnosis , Engine electronics and Final con-
es, in part or in w
trol diagnosis .
t to the co
for fuel pump electronics.
rrectness of i
The fuel pump must now run slowly up to maximum speed.
l purpos
Note
nf
ercia
or
satelettronica
m
m
atio
The fuel pump runs very quietly.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
If fuel pump does not run:
o
m
f
en
ng
t.
yi Co
op py
72 ; Rear seats; Removing and installing bench seat . t. C rig
gh ht
pyri by
Vo
o
by c lksw
– Pull connector off fuel pump control unit - J538- . cted agen
Prote AG.
– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
Voltage supply not OK:
– Locate and rectify open circuit referring to current flow diagram
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
Voltage supply OK:

fuel delivery unit.
– First check that the connector -arrow- is fitted securely by

pulling the connector without pressing the catch. If connector
was not inserted correctly, repeat functional check of fuel
pump.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.
satelettronica
WARNING

connections. Then release pressureagen by carefully A
AG. Volkswagen pulling
G do hose
off connection. y Volksw es n
ot g
b ua
ed ran
oris tee
th or
au ac
ss
– Pull fuel lines -1- and -2- off the flange.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n

h re
hole
spec

es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia
– Check that electrical wires between flange and fuel pump are
connected.
m
at
om
ion
c
If no open circuit can be found:

in t
or
his
te
– Fuel pump defective, renew fuel delivery unit ⇒ page 181 .

a
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.
3.5.2 Checking fuel pressure
WARNING


off connection.
– Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
Press in securing ring to release fuel line. 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
– Connect pressure tester - VAS 6550- to fuel supply line with
wit
, is n
satelettronica
adapter - VAS 6550/1- and -VAS 6550/2- .
h re
hole
spec
– Make sure that drain tap is closed and cut-off taps are open.
es, in part or in w
t to the co
– Actuate fuel pump with final control diagnosis to build up fuel
pressure.
– Read fuel pressure on pressure gauge.
rrectness of i
• Specification: 4.0 to 7.0 bar
l purpos
If fuel pressure is OK, check holding pressure ⇒ page 189 .
nform
ercia
If the specification is exceeded:

m
at
– Check return line between fuel filter and fuel pump for kinks
om
ion
and blockages.
c
in t
or
his
te
If no fault is found:
a
do
priv
cum
or
– Pressure limit valve in fuel filter is defective. Renew fuel filter.

f
en
ng
t.
yi Co
If specification is not obtained Cop py
t. rig
gh ht
yri
– Check fuel pressure upstream of fuel filter; proceed as follows: p by
co Vo
by lksw
cted agen
Prote AG.
– Pull fuel supply line -arrow- off fuel filter.

AG. Volkswagen Plus
lkswGolf
agen 2004 ➤ , GolfAG does 2005 ➤ , Tiguan 2008 ➤ , Touran 2003 ➤
not
d by V engine (1.4 l, EA 111, turbocharger,
o gu
ara supercharger) - Edition 08.2017
e nte
oris eo
– Connect pressure th
au tester - VAS 6550- between fuel filter and ra
c
fuel supply line with adapter - VAS 6550/1- and -VAS 6550/2- .
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Start engine and run at idling speed.
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
– Slowly close cut-off tap -A-. Pressure must rise to at least
r
rp
satelettronica
7.0 bar. When 7.0 bar is reached, open shut-off tap again im‐
um
fo
en
g
mediately.
n
t.
yi Co
Cop py
If pressure has risen:
t. rig
gh ht
pyri by
Vo
o
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐
c by lksw
cted agen
tive. Renew fuel filter. Prote AG.
If pressure does not rise:

3.5.3 Checking holding pressure

• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 187 .
Test sequence
pressure.
– Watch pressure drop on pressure gauge. Pressure must re‐
main above 3.0 bar for 10 minutes.
If the pressure drops further:
pressure.

– After pressure has built up, close cut-off tap -B- of pressure
tester immediately. Lever is then at right angle to direction of
flow.
If the pressure does not drop now:
Note
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side. gen AG
. Volkswagen AG
d a oes
ksw not
Vol gu
by
– Check fuel pipe to high-pressurerispump
ed for leaks. ara
nte
tho eo
If no fault is found: au ra
c
ss
ce
e
– Renew high-pressure pump ⇒ page 307 .

nl
pt
du
an
itte
If the pressure drops again:
y li
erm
ab
ility
Leak must be sought on fuel tank side; proceed as follows:
ot p
wit
, is n
– Check fuel supply line to fuel filter for leaks.
h re
hole
spec
satelettronica
If no fault is found on the fuel line:
es, in part or in w
t to the co
– Check pressure retention valve in fuel delivery unit. Proceed
as follows:
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
– Connect pressure tester - VAS 6550- between fuel filter and
agen
Prote AG.
pressure.

– After pressure has built up, close cut-off tap -A-.

– Pressure retention valve in fuel pump defective; renew fuel
delivery unit ⇒ page 181 .
If the pressure does not drop:
– Pressure retention valve in fuel filter is OK, pressure limiting
valve in fuel filter is defective. Renew fuel filter.
3.5.4 Checking fuel delivery

wage rate
n AG. V olkswagen AG
does
olks not
yV gu
db ara
rise nte
Note tho eo
au ra
c
ss
ce
le
When driving characteristic problems occur when the fuel tank is

un
pt
an
d
a approx. 1/4 filled, then check fuel delivery rates with approx. 1/
itte
y li
rm
ab
4 filled tank or less.
satelettronica
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
fuel delivery unit.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
op
pulling the connector without pressing the catch. The connec‐ C py
t. rig
tor can cause a fault if it has not been fitted correctly.
gh ht
pyri by
Vo
o
by c lksw
– Now pull off connector. Prote
cted AG.
agen

unit for damage.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
WARNING

off connection.
satelettronica
fuel with a cloth. wage
e ks s no
Vol t gu
d by ara
e nte
ris
Note tho eo
au ra
c
ss
ce
le

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

adapter - VAS 6550/2- . Hold adapter - VAS 6550/1- in a mea‐
suring container.
rrectne
ss o
cial p
WARNING
inform
mer
Danger of spraying! Wear protective goggles and protective

atio
m
clothing to avoid injury and contact with the skin. Hold contain‐
o
n
c
i
or
er in front of open connection of pressure tester.

thi
te
sd
iva
o
pr
cum
r
fo
– Operate remote control - V.A.G 1348/3A- . Then slowly close

en
ng
t.
yi
shut-off tap -arrow- until a pressure of 4 bar is displayed on
Co
op py
pressure gauge. From this point on do not move position of
t. C rig
gh ht
yri
shut-off tap. p by
o Vo
by c lksw
cted agen
– Drain measuring container. Prote AG.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, also connect multimeter - V.A.G 1715-
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
VAS 5565- .
– Operate remote control for 60 seconds while measuring volt‐
age at fuel pump. olkswage es n
o
yV t gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Compare quantity of fuel delivered with specification.
wit
is n
h re
ole,
*) Minimum delivery rate cm3/60 s
spec
**) Voltage at fuel pump with engine not running and pump run‐
t to the co
ning.
Reading example:
rrectne
During the test a voltage of 10.5 volts is measured. This equates
satelettronica
to a minimum delivery rate of approx. 1200 cm3/60 s.
ss o
cial p
f
If specification is not obtained
inform
mer
– Check fuel lines for possible restrictions (kinks) or blockages.

atio
om
n
c
i
or
n thi
e
– Remove cap from fuel filler neck and repeat check. If fuel de‐
t
sd
iva
livery rate is now reached, check fuel tank breather.

pr
cum
r
fo
en
ng
If reading again does not match specification:

t.
yi Co
Cop py
– Check fuel filter (proceed as follows):
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING
Prote AG.

off connection.


suring container.
shut-off tap.
– Drain measuring container.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
– Renew fuel delivery unit.
satelettronica
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):
– Measure current draw of fuel pump ⇒ page 194 .
3.5.5 Checking current consumption

72 ; Rear seats; Removing and installing
gen AG
. Volkswabench
gen AG seat .
a does
lksw n
– Remove cover -1- with db
y Vfuel pump control unit - J538- -2-
o ot g
uafrom
fuel delivery unit.orise ran
te
th eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne
pulling the connector without pressing the catch. The connec‐

ss o

cial p
f inform

mer
unit for damage.

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.


– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
gen AG
. Volkswagen AG
a does
lksw not
– Measure current draw ofd bfuel
y V pump.
o gu
ara
e nte
ris
• Specification: max.uth9o amps eo
ra
a c
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ The starting current for the fuel pump can be briefly above
ility
ot p
specifications when starting the engine.
wit
, is n
h re
♦ If the fault in the fuel system is not always evident, the check
hole
spec
can also be carried out during a road test. A 2nd person is
es, in part or in w
required to do this, however.
t to the co
If the current draw is exceeded:
rrectness of i
satelettronica
l purpos
nform
ercia
unit (Touran)
m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
um
for

en
ng
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
♦ Key for union nut - 3217- cted agen
Prote AG.

Removing
Caution
Condition:
• Fuel tank must be filled no more than 3/4. This ensures
that the fill level is below the flange of the fuel delivery unit.
Note
♦ If necessary, drain fuel tank using fuel extractor - VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 158 .
♦ Observe rules for cleanliness ⇒ page 180 .

theft code.
n AG. Volkswagen AG
– With the ignition switched waoff,
ge disconnect battery
doesearth strap.
satelettronica
olks no t gu V
ara by
– Fold rear benchrisseat
ed forwards. nte
tho eo
– Release carpet
ss au
under rear bench seat and fold it back ⇒ Gen‐ ra
c
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment
ce
e
nl
trims; Removing and installing luggage compartment floor .

pt
du
an
itte
y li
– Remove cover from fuel delivery unit -arrows-.

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove cover -1- with fuel pump control unit -J538- -2- from
m
at
om
fuel delivery unit.

on
c
in t
or
his
ate
WARNING
do
priv
cum
for
en
g
n
t.
yi Co
op
gloves to avoid injuries and skin contact. Wrap a cloth around C py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.

– Pull connector -1- and fuel lines -2- and -3- off flange.
Note
– Fit union nut tool - 3217- on the three rounded ribs of the union
nut and unscrew union nut from flange. When doing this, press
union nut tool - 3217- firmly onto union nut.
Note
satelettronica
If delivery unit is to be renewed, drain old delivery unit before dis‐
posal. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
Installing ised b ara
nte
r
ho eo
– Installing
s aut the fuel delivery unit is carried out in reverse ra
c order
ofs removal.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
♦ When inserting fuel delivery unit, ensure that fuel gauge

hole
sender is not bent.

spec
es, in part or in w
t to the co
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
rrectness of i
♦ Note installation position of fuel delivery unit flange: mark on

flange must align with mark on fuel tank -arrows-.
l purpos
♦ Do not interchange supply and return lines.

nf
ercia

orm
m
atio
♦ After installing fuel delivery unit, check that the supply, return
om
and breather lines are still clipped onto the fuel tank.
n in
or c
thi
e
♦ Following installation, adapt fuel pump control unit - J538- to

t
sd
iva
engine control unit ⇒ Vehicle diagnostic tester “Guided Func‐

r
rp
cu
o
tion”.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
sender G (Touran)
cted agen
Prote AG.
Removing

– Pull fuel gauge sender - G- slightly to side and upwards at the

same time.
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
– If the sender cannot be released in this way, the retaining tabs
erm
ab
ility
-arrows- must also be pushed to the side slightly.
ot p
wit
is n
– Note colour co-ordination of cables for reinstallation.
h re
ole,
spec
t to the co
satelettronica
rrectness o
cial p
f inform
mer
– Release electrical connectors -1 to 3- and pull them off. Then atio

m
bend back locking lugs of connectors.

o
n
c
i
or
n thi
e
Installing:
t
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.
– Connect connectors -1…3-. Observe colour co-ordination.

– Check connectors are secured properly by pulling.
– Insert fuel gauge sender - G- into guide on fuel delivery unit
and press down until it engages.
3.8 Checking fuel pump (Touran)
Note


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Remote control - V.A.G 1348/3A- ss o
cial p

inform
mer

atio
om
♦ Key for union nut - 3217-

n
c
i
or
n thi
e

t
sd
iva
o
pr

um
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
Test conditions cop Vo
by lksw
cted agen
Prote
• Battery voltage at least 11.5 V
AG.
• Fuse for Fuel pump control unit - J538- OK.

Note
Function of fuel pump is checked using final control diagnosis.


driver footwell.
– One after other, press following buttons on display: “Vehicle
self-diagnosis”, “,01 - Engine electronics” and “Final control
diagnosis”.
Note
The fuel pump runs very quietly.

satelettronica
– Fold rear bench seat forwards.
– Release carpet under rear bench seat and fold it back ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment
AG. Volkswagen AG d
trims; Removing and installing luggage compartment
lksw
agen floor . oes
n o ot g
yV ua
edb ran
– Remove cover from fuel delivery unit
tho
ri-arrows-.
s tee
or
au 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
– Pull connector off fuel pump control unit - J538- .

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.

– Check voltage supply between contacts -1- and -6- using mul‐
timeter - V.A.G 1715- .
• Specification: approx. battery voltage
cations.
Voltage supply OK:
fuel delivery unit.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
satelettronica
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
pump.
es, in part or in w
t to the co
rrectness of i
unit for damage.
l purpos
WARNING
nform
ercia

m
a
com
ti

on in

r
te o
thi
off connection.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Pull fuel lines -1- and -2- off the flange. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.


– Fit union nut tool - 3217- on the three rounded ribs of the union
nut and unscrew union nut from flange. When doing this, press
union nut tool - 3217- firmly onto union nut.
connected.
If no open circuit can be found:
AG. Volkswagen AG d
agen oes
lksw not
o
byV gu
ara
ed
ris nte
ho eo
aut ra
WARNING ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
satelettronica
, is n
h re
off connection.
hole
spec
es, in part or in w
t to the co
fuel with a cloth.
rrectness of i
Note
l purpos
Press in securing ring to release fuel line.
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
adapter - VAS 6550/1- and -VAS 6550/2- . ht. rig
rig ht
py by
o Vo
– Make sure that drain tap is closed and cut-off taps are open. by c lksw
cted agen
Prote AG.
pressure.
If fuel pressure is OK, check holding pressure ⇒ page 189 .
If the specification is exceeded:
– Check return line between fuel filter and fuel pump for kinks
and blockages.
– Pressure limit valve in fuel filter is defective. Renew fuel filter.
– Check fuel pressure upstream of fuel filter; proceed as follows:


satelettronica
. Volkswage
– Slowly close cut-off tap -A-. Pressure mustksrise
wageto at least
n AG n AG d
oes
not
7.0 bar. When 7.0 bar is reached, openbyshut-off
Vol
tap again im‐ gu
ara
mediately. ris
ed
nte
tho eo
If pressure has risen: ss au ra
c
ce
le
– Fuel pump is OK. Pressure limiting valve in fuel filter is defec‐

un
pt
an
d
tive. Renew fuel filter.

itte
y li
rm
ab
If pressure does not rise:

pe
ility
ot
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
3.8.3 Checking holding pressure

rrectness of i

l purpos

Test sequence
nform
ercia

m
pressure.
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.


pressure.
flow.
Note
engine side.
– Check fuel pipe to high-pressure pump for leaks.

If the pressure drops again: wage
es n
lks ot g
Vo
satelettronica
Leak must be sought on fuel tank side; proceed d by as follows: ua
ran
ir se tee
o
– Check fuel supply line to fuel filterau for leaks.
th or
ac
ss
If no fault is found on the fuel line:
ce
e
nl
pt
du
an
– Check pressure retention valve in fuel delivery unit. Proceed
itte
y li
as follows:
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
a
iv
o
r
rp
cu
o
f
en
ng
t.
yi Co
op
C py
t. rig
gh
pressure.
ht
pyri by
Vo
co lksw
by
– Read fuel pressure on pressure gauge. cted agen
Prote AG.

AG. Volkswagen AG d
– After pressure has built up, close cut-off tap -A-. agen oes
olksw not
y V gu
d b ara
– Watch pressure drop on pressure gauge. Pressure must orise re‐ nte
main above 3.0 bar for 10 minutes. auth eo
ra
ss c
ce
e
nl
pt
du
an
– Pressure retention valve in fuel pump defective; renew fuel
itte
y li
delivery unit ⇒ page 195 .
erm
ab
ility
ot p
If the pressure does not drop:
wit
, is n
h re
– Pressure retention valve in fuel filter is OK, pressure limiting
hole
spec
valve in fuel filter is defective. Renew fuel filter.
es, in part or in w
t to the co
3.8.4 Checking fuel delivery rate
rrectness of i
l purpos
Note
nf
ercia
o
rm
m
atio
om
n in
satelettronica
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Remove cover -1- with fuel pump control unit - J538- -2- from Cop py
t. rig
fuel delivery unit. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

unit for damage.


– Connect remote control - V.A.G 1348/3A- to adapter - VAS
5565- and to battery positive terminal in engine compartment.
AG. Volkswagen AG d
agen oes
Note yV
olksw not
gu
d b ara
ise nte
r
This step serves only to have the fuel pumputhrunning when the
o eo
ra
engine is stopped. ss a c
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
off connection.
rrectness of i
satelettronica
l purpos
fuel with a cloth.
nform
ercia
Note
m
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.

suring container.
WARNING
Danger of spraying! Wear protective goggles and protective

clothing to avoid injury and contact with the skin. Hold contain‐
er in front of open connection of pressure tester.

shut-off tap.

. Volkswagen AG
gen AG d
Golf 2004 ➤ , Golf Plus olks 2005 ➤ , Tiguan 2008 ➤
wa oes
n,oTouran
t gu 2003 ➤
yV
4-cylinder direct-injection engine (1.4 l, EA is111,
ed b turbocharger, supercharger) - Editionara 08.2017
n
r tee
ho
ut or
– The quantity delivered by the fuel on the bat‐ pump sdepends
s a ac
tery voltage. Therefore, also connect multimeter - V.A.G 1715-
ce
le
un
pt
to outputs -1 and 5- of test instrument/DSO adapter 5-pin -
an
d
itte
VAS 5565- .
y li
erm
ab
ility
ot p
wit
age at fuel pump.
is n
h re
ole,
spec
t to the co
rrectnes
– Compare quantity of fuel delivered with specification.
s o
cial p
f i
*) Minimum delivery rate cm3/60 s
nform
mer
atio
m
ning.
o
n
c
i
or
n thi
e
Reading example:
t
sd
iva
o
pr
c
um
r
fo
satelettronica
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
– Check fuel lines for possible restrictions (kinks) or blockages. by c lksw
cted agen
Prote AG.
– Check fuel filter (proceed as follows):
WARNING

off connection.


suring container.
shut-off tap.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained
– Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
– Renew fuel delivery unit.
satelettronica
If fuel delivery rate has been attained, but nevertheless you sus‐
pect a fuel supply system fault (e.g. intermittent failure of fuel
supply system):

n AG. Volkswagen A ge G do
swa es
– Remove cover b-1- y V with fuel pump control unit - J538-
olk not
gu -2- from
ara
fuel deliveryrisunit.
ed
nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne

ss

o
cial p
f inform

mer
unit for damage.

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.


5565- .
– Measure current draw of fuel pump.
• Specification: max. 9 amps
Note
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:
satelettronica

unit (Tiguan)
Note
. Volkswagen AG
gen AG does
swa
After removing bfuel
y V delivery unit, check fuel tank tfor
olk no
gu heavy soiling
and clean ifrisnecessary.
ed
ara
nte
ho eo
aut ra
Specials tools and workshop equipment required
s 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

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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Cop py
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3.9.1 Removing
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yV
Caution ir se
d b ua
ran
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th or
u
Condition: ss
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un
• Fuel tank must be filled no more than 1/2. This ensures
pt
an
d
itte
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that the fill level is below the flange of the fuel delivery unit.
rm
ab
pe
ility
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wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
If necessary, drain fuel tank using fuel extractor - VAS 5190- .
rrectness of i
l purpos

nform
ercia
theft code.
satelettronica
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a
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tion in
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te o
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WARNING t. C rig
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by
Fuel system is under pressure! Wear eye protection and gloves Prote
cted AG.
agen
– Check that the connector is fitted securely by pulling the con‐

nector without pressing the catch.
Note
Check the contacts on the connectors for damage.
– Pull connector -1- and fuel line -2- off right flange (in direction
of travel).

– Release connector -arrow- on fuel pump control unit - J538-

using assembly tool - T10118- and pull it off.
AG. Volkswagen AG d
agen oes
olksw not
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spec
– Slightly raise fuel delivery unit and remove seal out from aper‐
t to the co
ture in fuel tank.
rrectness
satelettronica
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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– Release fuel hoses on delivery unit -arrows- and pull delivery

iv
o
pr
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unit out of fuel tank.
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t.
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Cop py
t. rig
Note opyri
gh by
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cted
If delivery unit is to be renewed, drain old delivery unit before dis‐
agen
Prote AG.
posal.
3.9.2 Installing
– Installing the fuel delivery unit is carried out in reverse order
of removal.
Note
♦ Fuel hoses are allocated to respective unions.

♦ Ensure plug-in connectors are secured properly by pulling.
♦ When inserting the fuel delivery unit, ensure that the fuel
gauge sender - G- is not bent.
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
♦ Moisten seal with fuel only when installing fuel delivery unit.
♦ Note installation position of flange for fuel delivery unit: tab
-1- must point in direction of travel. The fuel delivery unit flange
can only be installed in this position.


sender G (Tiguan) swa
gen AG
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does
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– Remove fuel delivery unit ⇒ page 209 . yV gu
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ris nte
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♦ Welding wire (2 mm thick)
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nl
pt
du
an
– Bend an 80 mm long welding wire as shown.
itte
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erm
ab
Dimension -a- = 10 mm
ility
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Dimension -b-: 70 mm
h re
hole
spec
Removing
es, in part or in w
t to the co
– Release connectors of wiring for fuel gauge sender -2-, and
pull off.
rrectness of i
l purpos
nform
ercia
satelettronica
– Press welding wire -1- in direction of -arrow- into recess be‐
m
at
neath sender.
om
ion
c
in t
– At the same time, push fuel gauge sender -2- from guides in
or
his
e
direction of -arrow-.
at
do
priv
c
Installing
um
for
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ng
t.
yi
– Insert fuel sender into guides on fuel delivery unit and press
Co
op py
downwards until it engages.
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rig by
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– Reconnect connector and check that it has engaged correctly. by c lksw
cted agen
Prote AG.
3.11 Removing and installing suction-jet

pump (Tiguan)

Note
♦ On vehicles with all-wheel drive, a suction-jet pump must

pump the fuel from the area of fuel gauge sender 2 - G169- to
the fuel pump due to the shape of the fuel tank.
♦ The fuel delivery unit must first be removed to remove the
satelettronica
suction-jet pump.
♦ Checking is only necessary when the engine stops due to lack
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
3.11.1 Removing
– Remove fuel delivery unit ⇒ page 209 . agen
AG. Volkswagen AG d
oes
olksw not
– Remove left cover (as seen facing direction of normal travel) d by V gu
ara
from fuel gauge sender 2 - G169- . horise nte
eo
ut ra
a
– First check that the connector is fitted securely byss pulling the c
connector without pressing the catch. The connector can
ce
le
un
pt
cause a fault if it has not been fitted correctly.
an
d
itte
y li
rm
ab
– Pull connector -1- off left flange.
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
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cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– Slightly raise flange and remove seal out from opening in fuel
tank.
– Pull flange together with fuel gauge sender 2 - G169- out of
fuel tank.
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
3.11.2 Installing
Caution
When installing do not bend fuel gauge sender 2 - G169- float

arm.
satelettronica
– Install flange together with fuel gauge sender 2 - G169- in fuel
tank. The lug on the flange points in direction of travel.
– Place fuel lines in right chamber of fuel tank ensuring they are
not kinked.
– Place a new flange seal dry into aperture in fuel tank and
moisten only inside (contact to flange) with fuel.
– Note installation position of fuel gauge sender 2 - G169- ⇒
page 173
– Check for correct position of seal.
– Tighten locking ring using wrench - T10202- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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nl
pt
du
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erm
ab
ility
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, is n
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hole
spec
– Reconnect connector -1- and check it is secured properly by

es, in part or in w
pulling.
t to the co

rrectness of i
Further assembly is performed in the reverse order of removal.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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214
cop Vo
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Rep. gr.20 - Fuel supply system Prote
cted AG.
agen
AG. Volkswagen
3.12 Removing and installing
Vol
ksw
agen fuel gauge
AG do
es n
ot g
sender 2 - G169- (Tiguan)
by ua
ed ran
ris te
tho eo
– Removing and installing
ss
ausuction-jet pump (Tiguan) ⇒ page ra
c
212
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Welding wire (2 mm thick)
ility
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wit
– Bend an 80 mm long welding wire as shown.
, is n
h re
hole
Dimension -a- = 10 mm
spec
es, in part or in w
Dimension -b-: 70 mm
t to the co
Removing
rrectness of i
– Release connectors for lines for fuel gauge sender 2 -
G169- -2- and pull off.
l purpos
nform
mercia
at
om
io
satelettronica
n
c
in t
or
– Press welding wire -1- in direction of -arrow- into recess be‐
his
ate
neath sender.
do
priv
cum
or
– At the same time, push fuel gauge sender 2 - G169- -2- from
f
en
ng
t.
guides in direction of -arrow-.
yi Co
Cop py
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Installing gh ht
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by c lksw
– Insert fuel gauge sender 2 - G169- into guides and press down Prote
cted AG.
agen
until it engages.
– Reconnect connector and check that it has engaged correctly.
3.13 Checking fuel pump (Tiguan)
Note


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
♦ Remote control - V.A.G 1348/3A-
es, in part or in w
t to the co

rrectness of i

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nform
ercia
Check function and voltage supply ⇒ page 216 .

m

at
om
ion
c
Checking holding pressure ⇒ page 219 .

in t
or
his
ate
Checking fuel delivery rate ⇒ page 220 .

do
priv
cum
or
Checking current draw ⇒ page 222 .

f
en
ng
t.
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op
C py
ht. rig
rig ht
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• Battery voltage at least 11.5 V by c lksw
cted agen
Prote AG.
• Fuse for fuel pump on fuse holder OK ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.

Test sequence
Note
Function of fuel pump is checked using final control diagnosis.

driver footwell.
– Press buttons on display one after the other for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

satelettronica
Note
. Volkswagen AG
gen AG does
The fuel pumpVruns
olks very quietly.
wa not
by gu
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– Switch
utho off ignition. eo
ra
s a c
s
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un
pt

an
d
itte
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rm
ab
pe
ility
– Remove right (in direction of travel) cover from fuel delivery

ot
wit
, is n
unit.
h re
hole
spec
es, in part or in w
Note
t to the co
For vehicles with auxiliary heater the metering pump - V54- con‐
rrectness of i
nector must be separated additionally.

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– First ensure that 5-pin wiring connection -1- is secure by

nform
ercia

m
pump.
a
com
tion in
– Now pull off connectors -1-.

r
te o
thi
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iva

do
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rp
unit for damage.

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fo
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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.


– Connect multimeter - V.A.G 1715- to contacts -1- and -5- of
adapters - VAS 5565- .
– Actuate fuel pump with final control diagnosis.
• The voltage must rise up to battery voltage during final control
diagnosis.
cations.
Voltage supply OK:
connected. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
If no open circuit can be found: d by ua
ran
ise tee
or
– Fuel pump defective, renew fuel delivery unit th⇒ page 209 . or
satelettronica
au ac
ss
ce
e

nl
pt
du
an
itte
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erm
Test conditions:
ab
ility
ot p
• Function of fuel pump has been checked ⇒ page 216 .
wit
, is n
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Test sequence
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
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off connection.
nform
mercia
at
om
i
– Pull off supply line (metal coupling) -2- and catch escaping fuel
on
c
with a cloth.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
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adapter - VAS 6550/1- and -VAS 6550/2- .
pressure.
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wage oes
• Specification: 4.0 to y7.0
Vol bar
ks not
gu
b ara
ed
If fuel pressure is hOK,
or
is check holding pressure ⇒ page 219 . ntee
t or
au ac
If specificationssis not obtained
ce
e
nl
pt
– Renew left flange with pressure limiting valve, suction jet pump
du
an
itte
and fuel filter.
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Pressure limiting valve and fuel filter are integrated into fuel gauge
es, in part or in w
t to the co
sender 2 - G169- with suction-jet pump and cannot be renewed
individually.
satelettronica
rrectness of i
– Repeat check.
l purpos

nform
mercia
3.13.3 Checking holding pressure at

om
ion
c
in t
or

his
ate
do
riv

p
cum
or

f
en
ng
t.
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Test sequence Cop py
t. rig
gh ht
yri
– Actuate fuel pump with final control diagnosis to build up fuel p by
o Vo
by c lksw
pressure. Prote
cted AG.
agen

pressure.
flow.
Note
engine side.
– Check fuel pipe to high-pressure pump for leaks.



If the pressure drops again:
Leak must be sought on fuel tank side; proceed as follows:
– Check fuel line to flange for leaks.
If no fault is detected on »external« fuel lines, search for leak in
fuel tank. Proceed as follows:
– Open flanges on left and right. Ensure all hose connections
are fitted correctly and do not leak.
– First renew left flange with pressure limiting valve and fuel fil‐
ter. Repeat pressure retention test. If leak is still present, non-
return valve in fuel pump leaks, renew fuel delivery unit.
3.13.4 Checking fuel delivery rate
Note
satelettronica
Test conditions
• Voltage supply OK.
72 ; Rear seats; Removing and installing bench seat . n AG. Volkswagen AG
age does
ksw
– Remove right (in direction of travel) cover from by fuel delivery
Vol
not
gu
ara
unit. ris
ed
nte
ho eo
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ss c
Note
ce
e
nl
pt
du
an
itte
y li
For vehicles with auxiliary heater the metering pump - V54- con‐
erm
ab
nector must be separated additionally.

ility
ot p
wit
, is n
h re

hole
spec

es, in part or in w

t to the co

rrectness of i
unit for damage.

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.


– Connect remote control - V.A.G 1348/3A- to test instrument
adapter/DSO (5-pin) - VAS 5565- and to battery positive (+).
– Pull off supply line (metal coupling) -2- and catch escaping fuel
satelettronica
with a cloth.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
s s a c
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
suring container.
rrectness of i
l purpos
WARNING nform
ercia
Danger of spray when shut-off tap is opened. Wear eye pro‐

tection and protective clothing to avoid injuries and skin con‐
m
at
om
tact. Hold container in front of open connection of pressure

ion
c
tester.
in t
or
his
ate
do
priv
cum
or

f
en
ng

t.
yi Co
op
pressure gauge. From this point on do not move position of C py
t. rig
shut-off tap.
gh ht
pyri by
Vo
co lksw
by
– Drain measuring container. cted agen
Prote AG.

– The quantity delivered by the fuel pump depends on the bat‐

tery voltage. Therefore, connect multimeter - V.A.G 1715- to
wires -1- and -5- of adapter - VAS 5565- in addition.
age at fuel pump.
lkswage es n
Vo ot g
– Compare quantity of fuel delivered d by with specification. ua
ran
ir se tee
o
Minimum delivery rate cms3a/60
h
*) u s
t or
ac
s
ce
e
nl
pt
du
ning.
an
itte
y li
erm
ab
Reading example:
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
– Check fuel lines for possible restrictions (kinks) or blockages.
rrectness of i
l purpos

nf
ercia
or
– Open flanges on left and right. Ensure all hose connections
m
m
atio
are fitted correctly and do not leak. Check sieve in fuel delivery
om
n in
unit and fuel tank for coarse soiling.

or c
thi
te
sd
iva
o
r
rp
cu
– First renew left flange with pressure limiting valve and fuel fil‐
o
m
f
en
ng
ter. Repeat delivery rate check. If fuel delivery is still insuffi‐

t.
yi Co
op
cient, fuel pump defective, renew fuel delivery unit. C py
t. rig
gh ht
yri by
If the fuel delivery rate has been attained but a fault is still sus‐ cop Vo
by lksw
pected in the fuel supply system (e.g. intermittent failure of fuel cted agen
Prote AG.
supply system):

unit.


unit for damage. wage
e ks s no
Vol t gu
d by ara
e nte
ris
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
5565- .
t to the co
rrectness of i
– Measure current draw of fuel pump.
satelettronica
l purpos
• Specification: max. 16 amps
nf
ercia
Note
orm
m
atio
m
o
n in
or c

thi
te
sd
iva
♦ If the fuel system malfunction is intermittent, you can perform

o
r
rp
cu
the check during a road test, but a 2nd person is necessary.

o
m
f
en
ng
t.
yi Co
op py
If the current draw is exceeded: t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
3.14 Removing and installing fuel pump con‐

trol unit - J538- (Tiguan)
Note
The fuel pump control unit - J538- is installed on the fuel tank.

♦ Commercially available flat-bladed screwdriver (blade width
120 mm)
Fuel pump control unit - J538- fitting location
1 - Bracket for fuel pump control unit - J538-
2 - Fuel pump control unit - J538-
3 - Connector
Removing
unit.

– Pull off connector -1-.
– Slide screwdriver -2- into bracket recess -1- directly above

plug.
– Swivel screwdriver in direction of -arrow-.
G. Volkswagen nA AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
satelettronica
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Press screwdriver down in direction of -arrow- and pull control spec

unit out of bracket at plug at same time.

t to the co
– Pull connector off control unit.

Installing
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Reconnect plug -3- to control unit -2-.

i
o
pr
cum
r
fo
en
ng
– Slide control unit -2- into bracket -1- until it engages.

t.
yi Co
Cop py
Further installation is carried out in reverse order of removal. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
4 Repairing electronic power control yV
b gu
d ara
ise nte
r
(EPC) ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
Removing and installing accelerator module (Golf, Golf Plus,
y li
erm
ab
Tiguan) ⇒ page 225 .
ility
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wit
Removing and installing accelerator module (Touran) ⇒ page
, is n
h re
226 .
hole
spec
es, in part or in w
t to the co
1 - Connector
rrectness of i
❑ Black, 6-pin.
l purpos
2 - Accelerator position sender

- G79- and accelerator position
nform
ercia
sender 2 - G185-
❑ Openings -A- for re‐
m
at
om
i
lease tool.
on
c
satelettronica
in t
or
❑ To remove, remove
his
te
dash panel cover and

a
do
riv
pedal cluster cover.

p
cum
for
en
g

n
t.
yi Co
accelerator module Cop py
. rig
(Golf, Golf Plus, Tiguan)
ht ht
rig by
py
⇒ page 225 . co Vo
by lksw
cted agen
❑ Removing and installing Prote AG.
accelerator module
(Touran) ⇒ page 226 .
3 - 10 Nm
4 - Protective cap
4.2 Removing and installing accelerator

module (Golf, Golf Plus, Tiguan)
4. Repairing electronic power control (EPC) 225

♦ Release tool - T10238-
♦ Release tool - T10240- (for right-hand drive) n AG. Volkswagen AG do

lkswage es n
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byV ua
d ran
ir se tee
tho
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un
pt
an
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rm
satelettronica
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Procedure
rrectness of i
– Remove pedal cluster cover.
l purpos
– Pull connector off accelerator module.

– Pull off protective cap in upper area of accelerator module.
nform
ercia
– Remove securing bolt.

m
a
com
tio
– To remove accelerator module, push release tool - T10238- n in
r
(for right-hand drive models) -T10240- into openings provided

te o
thi
to stop.
s
iva
do
r
rp
cum
– Pull out accelerator pedal module vertically.

fo
en
ng
t.
yi Co
Install in reverse order of removal. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.3 Removing and installing accelerator

module (Touran)

♦ Release tool - T10269-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
♦ Release tool - T10297- (for right-hand drive)
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
satelettronica
rrectness of i
l purpos
nform
ercia
Removing
m
a
com
tio
– Remove steering column cover -arrows-.
n in
r
te o
thi
– Pull connector off accelerator module. s
iva
do
r
rp
– Pull off cover cap in upper area of accelerator module.

um
fo
en
ng
t.
– Remove securing bolt.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– To remove accelerator module, push release tool - T10269-

(for right-hand drive models -T10297- ) into openings provided
to stop.
– Pull out accelerator pedal module vertically.
4. Repairing electronic power control (EPC) 227

Installing
– Push wiring guide -1- and electrical connector -2- onto accel‐
erator module.
– Press accelerator pedal module onto retaining pins -6-.
– Insert centring pin -7- into hole in underbody.
– Secure accelerator module with bolt -3-, specified torque
10 Nm and fit cap -4-.
– Install steering column trim.
satelettronica
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
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Cop py
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Prote AG.

5 Activated charcoal filter system

Assembly overview (Golf, Golf Plus) ⇒ page 229
Checking fuel tank breather (Golf, Golf Plus) ⇒ page 230
Note
♦ The fitting location for the activated charcoal

wage
n AGfilter
. Volksin the Touran
wagen AG
does
is on the fuel tank. by
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♦ Assembly overview - fuelthotank
ris (Touran) ⇒ page 165 e or
au ac
ss
Checking fuel tank breather (Touran) ⇒ page 231
ce
e
nl
pt
du
an
Assembly overview (Tiguan) ⇒ page 232
itte
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Checking fuel tank breather (Tiguan) ⇒ page 233
ility
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es, in part or in w
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satelettronica
Note
rrectness of i
♦ Hose connections are secured with either spring-type or
l purpos
clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
nf
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o
♦ Spring-type clip pliers - VAS 5024A- are recommended for in‐
rm
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stallation of spring-type clips.
atio
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5.1 Assembly overview (Golf, Golf Plus)
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t.
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Cop py
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5. Activated charcoal filter system 229

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤au,thTouran 2003 ➤ ra
s c
4-cylinder direct-injection engine (1.4 l, EA 111,s turbocharger, supercharger) - Edition 08.2017
ce
le
un
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❑ Location: on right in en‐
ility
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gine compartment.
wit
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2 - Pressure retention valve
ole,
spec
with connecting hose
t to the co
3 - Connection hose
❑ From fuel tank
rrectne
4 - 10 Nm
ss o
cial p
f i
solenoid valve 1 - N80-
nform
mer
❑ Fitting location: behind
atio
intake manifold om
n
c
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or
n
❑ Valve closed with igni‐
thi
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tion switched off
t
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❑ When engine is warm,
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valve is activated
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(pulsed) by engine con‐ Cop py
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satelettronica
rig ht
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6 - Connection hose
by c lksw
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Prote AG.
❑ To intake manifold
7 - Bracket
❑ For activated charcoal
filter.
8 - Breather hose
9 - Sealing grommet
5.2 Checking fuel tank breather (Golf, Golf

Plus)
♦ Hand operated vacuum pump - VAS 6213-

AG. Volkswagen A
n G do
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♦ Adapter set - V.A.G ed 1318/17-
by ua
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pe
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spec
es, in part or in w
t to the co
rrectness of i
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• Ignition must be switched off.

Test sequence
nform
ercia
– Pull off breather line -1-. To do this, press release button.

m
a
com
tio
– Then connect hand vacuum pump - VAS 6213- using adapter
n in
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set - V.A.G 1318/17- to the activated charcoal filter line.
thi
satelettronica
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do
– Operate hand vacuum pump - VAS 6213- several times. There
r
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must be no development of vacuum.

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op
If vacuum builds up: C py
ht. rig
rig ht
– Check breather hose ⇒ Item 8 (page 230) on activated char‐
py by
co Vo
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coal filter for soiling and clean if necessary. Prote
cted AG.
agen
If vacuum does not build up:

– Hold breather fitting ⇒ Item 8 (page 230) closed and operate
vacuum pump again several times. Vacuum must build up.
– Renew activated charcoal filter.
5.3 Checking fuel tank breather (Touran)


Test sequence

– First disconnect white breather hose at hose connection -2-.
– Then connect hand vacuum pump - VAS 6213- to hose -1- as

shown.
If vacuum builds up:
– Check breather hose -3- on activated charcoal filter -2- for
soiling, and clean if necessary.
satelettronica
– Hold breather hose -3- shut and operate vacuum pump again
several times. Vacuum must build up.
– Renew activated charcoal filter -2-.
Note
The fuel tank will have to be removed in order to remove and

install the activated charcoal filter ⇒ page 170 .
AG. Volkswagen AG d
agen oes
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5.4 Assembly overview (Tiguan) yV
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by lksw
232
cted agen
Prote AG.
Rep. gr.20 - Fuel supply system

❑ Location: in rear right
wheel housing.
2 - Connection hose
❑ To remove, pull off at se‐
curing ring.
3 - From fuel tank
4 - Breather line
ter solenoid valve 1 -
N80-
❑ Clipped onto fuel tank.
5 - Breather line
❑ From activated charcoal
filter
❑ Valve closed with igni‐
satelettronica
tion switched off
❑ When engine is warm,
valve will be activated agen
AG. Volkswagen AG d
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(pulsed) by engine con‐ olksw not
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trol unit rised ara
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7 - Connection hose aut ra
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nl
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du
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itte
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8 - 10 Nm
ility
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spec
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5.5 Checking fuel tank breather (Tiguan)
l purpos

nf
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Cop py
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Test sequence

– Pull off breather line -1-. To do this, press release button.
lkswage es n
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byV ua
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nl
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du
an
itte
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ab
ility
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– Then connect hand vacuum pump - VAS 6213- as shown to
h re
hole
breather line.
spec
es, in part or in w
t to the co
– Detach hose -1- from activated charcoal filter.
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
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– Seal breather hole and connection on activated charcoal filter

at
do
riv
-arrows-, and operate vacuum pump several times again. Vac‐

p
cum
or
uum must build up.

f
en
ng
t.
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– If vacuum does not build up, renew activated charcoal filter. t. Cop py
rig
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pyri by
Vo
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21 – Turbocharging/supercharging
ara
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tho eo
s au ra
c
s
ce
le
1 Exhaust turbocharger
un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
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hole
♦ Secure all hose connections with hose clips which conform to
spec
production standard.
es, in part or in w
t to the co
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. The seals and sealing
surfaces must be oiled lightly for plug-in connectors ⇒ page
rrectness of i
276 .
l purpos
♦ Charge air system must be free of leaks.

♦ Renew self-locking nuts.
nform
ercia
♦ It is recommended that spring-type clips should be installed

m
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t
using spring-type clip pliers - VAS 5024A- or hose clamp pliers
ion in
- VAS 6340- .
r
te o
satelettronica
thi
s
iva
♦ Fill turbocharger with engine oil at oil supply line connection.
do
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♦ After installing turbocharger, run engine for about 1 minute at
en
ng
t.
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idling speed and do not rev up immediately. This ensures that
Co
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the turbocharger is fully primed with oil. t. C rig
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pyri by
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by
Assembly overview - turbocharger ⇒ page 235 . cted agen
Prote AG.
Removing and installing turbocharger ⇒ page 238 .

Checking turbocharger vacuum unit ⇒ page 244 .
Removing and installing vacuum unit for turbocharger ⇒ page
246 .
Adjusting vacuum unit for turbocharger ⇒ page 247 .
1.1 Assembly overview - turbocharger

Part I ⇒ page 236
Part II ⇒ page 237
1. Exhaust turbocharger 235

lkswage es n
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1.2 Part I
nform
mer
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by
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236 Rep. gr.21 - Turbocharging/supercharging

1 - Charge pressure control

solenoid valve - N75- AG. Volkswagen AG d
agen oes
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2 - 10 Nm byV
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3 - 7 Nm hor eo
aut ra
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4 - Turbocharger air recircula‐ ss
ce
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tion valve - N249-
nl
pt
du
an
itte
❑ To remove, pressure
y li
erm
ab
pipe must be removed ⇒
ility
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page 241 .
wit
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5 - O-ring
hole
spec
es, in part or in w
t to the co
⇒ page 238
rrectness of i
❑ Checking turbocharger
l purpos
vacuum unit ⇒ page

244 .
nform
ercia
satelettronica
vacuum unit for tur‐
m
at
bocharger ⇒ page
om
io
246 .
n
c
in t
or
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❑ Adjusting vacuum unit

at
do
riv
for turbocharger ⇒ page

p
cum
247 .
for
en
ng
t.
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7 - Connection hose . Cop py
rig
ht ht
rig
8 - Connection hose py by
co Vo
by lksw
cted agen
Prote AG.
1.3 Part II

1 - 8 Nm
2 - Coolant pipe
3 - O-ring
❑ Renew
4 - Stud, 20 Nm
❑ Coat with high-tempera‐
ture paste.
⇒ page 238
❑ Checking turbocharger
vacuum unit ⇒ page agen
AG. Volkswagen AG d
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244 . olksw not
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vacuum unit forautur‐
th
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bocharger ⇒ page
ss c
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246 .
nl
pt
du
an
❑ Adjusting vacuum unit
itte
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for turbocharger ⇒ page
ab
satelettronica
ility
247 .
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wit
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6 - Seal
h re
hole
spec
❑ Renew
es, in part or in w
t to the co
7 - 25 Nm
❑ Renew studs and fas‐
tening nuts. rrectness of i
❑ Coat studs with high-
l purpos
temperature paste.
Screw the studs into cylinder
nf
ercia
head until they project only

or
25 mm.
m
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Observe tightening sequence:

or c
thi
items -A- to -I-.

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8 - Coolant pipe
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t.
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9 - Seal
Co
Cop py
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❑ Renew opyri
gh by
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ht
c lksw
10 - 8 Nm
by
cted agen
Prote AG.
11 - Oil return pipe
12 - Banjo bolt, 30 Nm
13 - Seal
❑ Renew
14 - Oil supply pipe
Caution
Oil supply line must be
renewed when installing
a new turbocharger.
15 - Banjo bolt, 30 Nm
1.4 Removing and installing turbocharger


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ho eo
aut ra
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ab
ility
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spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
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c
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Removing en
ng
t.
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Cop py
ht. rig
Caution rig ht
py by
co Vo
by lksw
cted agen
If a mechanical fault is found on the turbocharger, e.g. a de‐
Prote AG.
stroyed compressor impeller, just renewing the turbocharger

is not enough. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the
charged air routing must be cleaned and the charge air cooler
must be renewed, if necessary.
Note

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐



off.
rection of -arrow-.

rection of -arrow-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
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un
pt
an
d
itte

y li
erm
ab
cooling system.
ility
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wit
is n
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ole,
Tiguan
spec
– Remove radiator fan - V7- together with cowling ⇒ page 144 .

t to the co

rrectne
Note
ss o
cial p
f inform
mer

atio
om
n
c
i
or
– Pull off connecting hoses -1- and coolant hoses -3-.

thi
te
sd
iva
– Unscrew bracket -2- and securing nuts -4- from turbocharger.

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.

– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe

.

Tiguan
G. Volkswagen
– Remove wiring lfor
ksw Lambda probe after catalytic
agen
A AG do
es n converter -
G130- and forV alternator from cable guides -arrows-.
o ot g
satelettronica
by ua
ed ran
oris tee
th or
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un
pt
an
d
itte
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erm
ab

ility
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G130- and remove.

wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
o
n
c
i
or

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.

– Unbolt exhaust pipe to rear silencer -arrows-.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
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un
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ab
ility
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spec
haust pipe to rear.
t to the co
– Also pull out exhaust pipe together with flexible joint.
Vehicles with all-wheel drive
rrectne
– The exhaust pipe is only loosened, not removed.
ss
satelettronica
cial p
f in
– Remove catalytic converter downwards.
form
mer
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
– Unscrew securing bolts for tensioning element -arrows- and
yi Co
op
remove it.
C py
t. rig
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yri by
– Remove air conditioner compressor ⇒ Heating, air condition‐ cop Vo
by lksw
cted agen
Prote AG.
Note

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
– Removing cowling with both radiator fans ⇒ page 142 .
– Unscrew securing bolt -arrow- for oil return pipe -2- from tur‐
bocharger.

– Pull oil return pipe downwards.

– Unbolt charge air hose -1- from turbocharger.
– Unscrew banjo bolts for oil supply pipe -arrows- from tur‐
bocharger and crankcase.
– Remove oil supply pipe.

– Unscrew all securing nuts from exhaust manifold -1-.
– Pull exhaust manifold out upwards with turbocharger.
Note
satelettronica
The turbocharger can only be renewed together with the exhaust
manifold. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
by ua
Installing ris
ed ran
tee
utho or
a ac
ss
Caution
ce
e
nl
pt
du
an
itte
Oil supply line must be renewed when installing a new tur‐

y li
erm
ab
bocharger.
ility
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wit
, is n
h re
hole
Installation is carried out in the reverse order. When installing, spec

note the following:
es, in part or in w
t to the co
♦ Renew studs and fastening nuts.

rrectness of i
♦ Screw the studs into cylinder head until they project only
25 mm.
l purpos
♦ Coat studs with high-temperature paste.

nf
ercia
♦ Observe tightening sequence and specified torques: items

o
-A- to -I- ⇒ page 237 .

rm
m
atio
m
♦ Renew seals, gaskets and self-locking nuts.

o
n in
or c
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♦ Fill turbocharger with engine oil at oil supply line connection.

te
sd
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rp
cu
♦ After installing turbocharger, run engine for about 1 minute at

o
m
f
idling speed to ensure that oil is supplied to turbocharger.

en
ng
t.
yi Co
op py
♦ Hose connections and hoses for charge air system must be t. C rig
gh ht
free of oil and grease before assembly. yri
p by
co Vo
by lksw
cted
agen
Prote AG.
♦ Install exhaust system and align it free of stress.
♦ When installing air pipes with plug-in connector, ensure that
securing clip -arrow- audibly engages into retaining lug -A-.
Fitting hose connections with plug-in connectors ⇒ page 276
Specified torques:
Assembly overview - turbocharger ⇒ page 235 .


Assembly overview - catalytic converter and add-on parts ⇒ page
330
Volkswagen AG
– Place vacuum hose -2- onto vacuum reservoir union
swa
g-1-.
en AG. does
olk not
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Note tho eo
au ra
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ce
Ensure that the vacuum hose is locked onto the union -2-. e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
yri by
-arrow- until it engages. op Vo
by c lksw
cted agen
Prote
AG.
1.5 Checking vacuum unit for turbocharger


– Check retaining clip -1- is seated correctly on vacuum unit

linkage.
Securing nut -2- must be locked with sealing paint.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Pull hose aut -arrow- off vacuum unit. 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
rrectne
– Fit hose -2- onto vacuum unit connection.

ss o
cial p
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to

inform
stop in direction of -arrow-.

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
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Vo
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by c lksw
cted agen
Prote AG.

Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , wTouran agen
AG.2003
Volksw➤
agen AG
does
ks n
by V turbocharger, supercharger) o- tEdition
o l
gu
a
08.2017
ed ran
oris tee
– Operate hand vacuum pump - VAS 6213- until au a pressure
th
of or
ac
700 mbar is displayed on pressure gauge.ss
ce
e
nl
pt
Linkage of vacuum unit -1- must move in direction of -arrow-.
du
an
itte
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erm
If pressure of 700 mbar is displayed:
ab
ility
ot p
Vacuum unit is OK.
wit
, is n
h re
If pressure drops abruptly:
hole
spec
es, in part or in w
– Renew vacuum unit ⇒ page 238 .
t to the co
rrectness of i
l purpos
1.6 Removing and installing vacuum unit for

turbocharger
nf
ercia
or
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atio
om
n in
or c
thi
te
sd
iva
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rp
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cu
o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
off.
rection of -arrow-.

– Pull hose -1- from pressure pipe and unscrew securing bolts
-2- for pressure pipe.
– Remove pressure pipe.
– Pull hose -arrow- from vacuum unit.

– Remove sealing paint from securing nut -2-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Pull off retaining clip -1- and loosen securing nut -2- on vacuum
un
pt
an
d
unit linkage.
itte
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rm
ab
– Unscrew knurled nut from vacuum unit stud.
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 securing bolts -arrows- for vacuum unit and remove

nform
ercia
vacuum unit from turbocharger.

m
a
com
Installing
ion in
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te o

thi
s
iva
note the following:

do
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rp
cum
fo
♦ Linkage must be adjusted after installing vacuum unit ⇒ page

en
ng
t.
yi
247 .
Co
Cop py
t. rig
♦ Specified torque for vacuum unit to turbocharger: 10 Nm
gh ht
pyri by
Vo
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by c lksw
♦ Renew seals, gaskets and self-locking nuts. cted agen
Prote AG.

free of oil and grease before assembly.
1.7 Adjusting vacuum unit for turbocharger
Note

The vacuum unit must be adjusted only if the linkage has been
loosened.

equipment required
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
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pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Pressure regulating valve - VAS 6342-

♦ Dial gauge set, 4-part - VAS 6341-
♦ Turbocharger tester - V.A.G 1397A-
♦ Dial gauge extension, 30 mm - VAS 6341/3- (not shown)
♦ Flat pickup - VAS 6341/4- (not shown)
Procedure
off.

rection of -arrow-.
lkswage es n
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byV ua
d ran
ir se tee
tho
or
– Unbolt heat shield over turbocharger -arrows-. s au ac
s
ce
e
nl
pt
du
cooling system.
an
itte
y li
erm
ab
– Now drain coolant.
ility
ot p
wit
, is n
h re
Note
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off connecting hoses -1- and coolant hoses -3-.

– Remove bolts and securing nuts -4- from turbocharger.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew securing bolt -2- and remove upper coolant pipe.
Note
The lower coolant pipe can only be removed following the removal
of the catalytic converter.
– Unscrew bolts -1- and remove pressure pipe.



Tiguan
G130- and for alternator from cable guides -arrows-. en AG. Volkswagen AG
ag does
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au ra
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nl
pt
du
an
itte
y li
G130- and remove.
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Remove catalytic converter downwards.
thi
te
sd
iva
– Pull hose -arrow- from vacuum unit on turbocharger.
o
r
rp
cu
o
m
f
en
ng
Checking vacuum unit adjustment ⇒ page 244 .

t.
yi Co
op py
Continuation if the vacuum unit has been renewed or the linkage
t. C rig
gh ht
yri
loosened p by
co Vo
by lksw
cted agen
– Remove sealing paint from lock nut -2-. Prote AG.
– Pull off retaining clip -1- and loosen lock nut -2- on vacuum
unit linkage.
– Adjust bypass flap -2- on vacuum unit linkage -1- via knurled
screw, so that bypass flap can just be turned by hand.

– Turn knurled nut 2 turns further.

– Tighten lock nut hand-tight.
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
– Connect hand vacuum pump - VAS 6213- , turbocharger tester
erm
ab
- V.A.G 1397A- to connection -II- and pressure control valve -
ility
ot p
VAS 6342- as shown in illustration.
wit
, is n
h re
– Close pressure control valve - VAS 6342- at lever -2-.
hole
spec
es, in part or in w
– Push sliding ring -1- on hand vacuum pump - VAS 6213- to
t to the co
pressure gauge in direction of -arrow-.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
satelettronica
rrectness of i
switch to position -II-.
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
– Secure universal dial gauge bracket - VW 387- to turbocharg‐ yri
gh by
ht
er.
op Vo
by c lksw
cted agen
Prote AG.
Note
The dial gauge linkage and the vacuum unit linkage must align.
– Secure dial gauge - VAS 6341/1- with dial gauge extension,

30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to uni‐
versal dial gauge bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Operate hand vacuum pump - VAS 6213- until a pressure of
800 mbar is displayed on turbocharger tester - V.A.G 1397A- .
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 0 mbar.
– Repeat this procedure approx. 3-5 times.
Note
This procedure is intended to prevent the vacuum unit bypass flap

or linkage from jamming.

Note
The values in mm refer to the read value (includes 1 mm preten‐

sion).

pressure reading drops to 0 mbar.
AG. Volkswagen AG d
agen
– Set dial gauge - VAS 6341/1- to 0. Volksw
oes
not
gu
d by ara
ise nte
or eo
h
ut
Note ss a ra
c
ce
e
nl
pt
♦ The following measurements must be performed in continuous du
an
itte
sequence. Do not allow the pressure to drop to 0 between
y li
erm
ab
measurements.
ility
ot p
wit
♦ Do not knock against linkage throughout the entire measure‐
, is n
h re
ment procedure.
hole
spec
es, in part or in w
– Operate hand vacuum pump - VAS 6213- until turbocharger
t to the co
tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
satelettronica
– Read off and note value indicated on dial gauge - VAS
rrectness of i
6341/1- .
l purpos
– Operate vacuum pump - VAS 6213- until turbocharger tester

- V.A.G 1397A- indicates 800 +/- 5 mbar.
nf
ercia
orm
pressure reading drops to 500 +/- 5 mbar.
m
atio
om
n in
– Read off and note value indicated on dial gauge - VAS
or c
6341/1- .
thi
te
sd
iva
o
r
– Add values 1 and 2 together and divide by 2.

rp
cu
o
m
f
en
ng
– The result (mean value) should be 5.5 +/- 0.25 mm.

t.
yi Co
Cop py
t.
– Correct setting if the result (average) is not 5.5 +/- 0.25 mm,
rig
gh ht
yri by
tighten lock nut hand-tight and repeat measurement. op Vo
by c lksw
cted agen
Prote
– If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock
AG.
nut to 9 Nm and secure with sealing paint.

– Secure retaining clip to vacuum unit linkage.
note the following:

♦ If renewed, place seal in groove of charge air hose. Ensure
seal is correctly seated in groove.
♦ Lightly moisten seal with engine oil.
♦ Bring retaining clip to release position -arrow-.
Specified torques:
Assembly overview - turbocharger ⇒ page 235 .

Assembly overview - charge air system ⇒ page 275 AG. Volkswagen AG d

agen oes
ksw
Removing and installing parts of exhaust system ⇒ bpage yV
ol 330 not
gu
ara
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rise nte
tho eo
au ra
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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
satelettronica
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Compressor
Assembly overview - supercharger ⇒ page 254
Removing and installing compressor (engine codes BLG, BMY)
⇒ page 255 .
AG. Volkswagen AG d
Removing and installing compressor (engine code BWK)
ksw ⇒ page
agen oes
not
263 . y Vol gu
db e
ara
ris nte
Removing and installing drive unit seal foruthsupercharger
o ⇒ eo
ra
page 271 ss a c
ce
e
nl
2.1 Assembly overview - supercharger
pt
du
an
itte
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erm
ab
ility
ot p
1 - Housing with noise insula‐
wit
, is n
tion
h re
hole
❑ For silencer.
spec
es, in part or in w
2 - Silencer
t to the co
❑ For intake air.
3 - Intake hose
satelettronica
rrectness of i
❑ Secure with spring-type
l purpos
clips
4 - 7 Nm
nf
ercia
o
❑ Self-tapping bolt
rm
m
atio
m
❑ The securing bolt may

o
n in
c
only be tightened using

or
thi
a power-operated
te
sd
iva
screwdriver if the screw‐
o
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rp
cu
driver speed is max.
o
m
f
en
ng
500 rpm and a max.

t.
yi Co
specified torque of 7 Nm Cop py
t. rig
is set. opyri
gh by
Vo
ht
by c lksw
5 - 7 Nm Prote
cted AG.
agen
6 - 7 Nm
a power-operated
500 rpm and a max.
specified torque of 7 Nm
is set.
7 - O-ring
❑ Renew
8 - Pressure pipe
9 - Noise insulation
10 - Housing
❑ For noise insulation.
11 - Silencer
❑ For charge air.
❑ With seal
❑ Renew seal between supercharger and intake silencer.
12 - Pulley

13 - 8 Nm n AG. Volkswagen AG do
lkswage es n
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yV
14 - Coolant pump with magnetic d b clutch for supercharger - N421-uaran
ir se tee
ho
15 - Poly V-belt aut or
ac
ss
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le
un
pt
an
d
itte
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Caution
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
leys and tensioning ele‐
t to the co
ment.
rrectness of i
16 - 23 Nm
l purpos
❑ For supercharger poly V-belt.
nform
ercia
❑ Relieve tension using 16 mm spanner.
satelettronica
m
a
❑ Lock with locking pin - T10060 A- .
com
tion in
r
18 - 40 Nm + 1/4 turn (90°) further

te o
thi
s
iva
do
❑ To loosen and tighten securing bolt, counterhold supercharger shaft with spanner.
r
rp
cum
fo
❑ Renew
en
ng
t.
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op
19 - Compressor
C py
t. rig
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yri
p by
co Vo
by lksw
cted
agen
Prote AG.
❑ Removing and installing drive unit seal for supercharger ⇒ page 271
20 - 25 Nm
2.2 Removing and installing compressor (engine codes BLG, BMY)
2. Compressor 255

equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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le

un
pt
an
d
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rm
ab
pe
ility

ot
wit
, is n
h re

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

rrectness of i
off.
l purpos
rection of -arrow-.
nform
ercia

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


rection of -arrow-.
– Detach spring-type clip from intake hose -arrow-.

– Remove securing bolt on silencer ⇒ Item 4 (page 254) .
AG. Volkswagen AG d
satelettronica
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
nform
ercia

m
at
om
– Remove securing bolt for charge air pipe -2-.

on
c
in t
or

his
ate

do
priv

um
for
en
ng
t.
yi
Co
Cop py
ht. rig
– Remove right drive shaft ⇒ Running gear, axles, steering; rig ht
py by
Vo
co lksw
by
cted agen
drive shafts . Prote AG.
2. Compressor 257
lkswage es n
Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan by V 2008 ➤ , Touran 2003 ➤ t gua
o o
ed ran
4-cylinder direct-injection engine ho
r (1.4 l, EA 111, turbocharger, supercharger)
is tee - Edition 08.2017
ut 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
– Unbolt exhaust pipe to front silencer -arrows-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

haust pipe to rear.
– Also pull out exhaust pipe together with flexible joint.


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Slacken supercharger poly V-belt by swinging
utho
tensioning ele‐ eo
ra
a
ment in direction of -arrow- with 16 mm
ss spanner. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
satelettronica
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing bolts -arrows- for tensioning element and
l purpos
remove tensioning element.
nform
– Tightly hold compressor shaft with a spanner -1-.
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.
2. Compressor 259
– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing
-arrows- outwards.
satelettronica
– Unscrew securing bolts -1- for supercharger and remove su‐
percharger together with intake silencer.
Removing intake silencer for charge air:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Pull intake silencer for charge air -2- together with pressure
un
pt
an
d
pipe in direction of -arrow-.

itte
y li
rm
ab
Installing
pe
ility
ot
wit
, is n
h re
Caution
hole
spec
es, in part or in w
When installing poly V-belts, observe direction of rotation and

t to the co
make sure they are properly seated on pulleys and tensioning

elements.
rrectness of i
l purpos
Note
nform
ercia
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 254) .

m
a
com
tio
♦ Before installing, lightly moisten O-rings with engine oil.

n in
r
te o
thi
♦ The pressure pipe can only be pushed in one position into the
s
iva
do
intake silencer for charge air (note locating element).

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
260
by lksw
cted agen
Rep. gr.21 - Turbocharging/supercharging Prote AG.
– Push intake silencer for charge air -2- together with pressure
pipe in direction of -arrow- into intake connecting pipe.
– Press intake silencer for charge air -2- against crankcase to
allow both dowel sleeves -3- to sit in holes.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Turn guide pins - T10341- hand-tight to stop in both lower

un
pt
threaded holes.
an
d
itte
y li
erm
ab
– Renew oil seal -1- and ensure it is correctly seated in the
ility
ot p
groove.
wit
is n
h re
– Push supercharger together with intake silencer onto guide
ole,
spec
pins - T10341- and tighten upper securing bolts hand-tight.
t to the co
– Remove guide pins - T10341- .
satelettronica
– Tighten lower securing bolts hand-tight.
rrectne
– Tighten securing bolts -1- evenly in diagonal sequence.
ss o
cial p
f
inform
mer
– Install poly V-belt -3- for compressor along with belt pulley.
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.
Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
– Hold supercharger shaft with 16 mm spanner -1-.
– Install tensioner.
2. Compressor 261
– Tighten bolts -arrows- to 23 Nm.
– Hold tensioner using a 16 mm spanner and pull out pin -

T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
satelettronica
– Press housing together with noise insulation against super‐
charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
♦ Renew securing bolt for supercharger pulley. Specified torque

an
itte
y li
40 Nm + 1/4 turn (90°) further.

erm
ab
ility
ot p

wit
, is n
h re

hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos

nform
ercia

m
Specified torques:
at
om
ion
c

in t
or
his
ate

do
priv
330
um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
262
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
Note

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
satelettronica
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
io
2.3 Removing and installing compressor (engine code BWK)

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Compressor 263
wage (1.4 l, EA 111, turbocharger,
4-cylinder direct-injectionVengine es n supercharger) - Edition 08.2017
olks ot gu
by ara
ed nte
Special tools and workshop oris eo
th
equipment required ss
au ra
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
va
satelettronica
i
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.

Removing
rection of -arrow-.

– Detach spring-type clip from intake hose -arrow-.
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
satelettronica
l purpos
nform
mercia
at
om
io
n
c
in t
or
his
e
– Remove securing bolt for charge air pipe -2-.

at
do
priv
c
um
for
en
ng
t.
yi Co
moving and installing noise insulation or skid plate . t. Cop py
rig
gh ht
– Remove poly V-belt ⇒ page 38 . pyri by
Vo
o
by c lksw
cted agen
– Remove right drive shaft ⇒ Running gear, axles, steering; Prote AG.
drive shafts .
2. Compressor 265
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
satelettronica
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
m
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;

o
n in
c
Rep. gr. 40 ; Lowering subframe .

or
thi
te
sd
a
– Remove exhaust pipe forwards.

iv
o
r
rp
cu
o
m
– Remove bevel box ⇒ 6-speed manual gearbox 0A6; Rep. gr.
f
en
ng
t.
yi
34 ; Removing and installing bevel box .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Slacken supercharger poly V-belt by swinging tensioning ele‐

ment in direction of -arrow- with 16 mm spanner.
satelettronica
olkswagen AG
en AG. V
– Unscrew securing bolts ks-arrows-
wag for tensioning element
does
not and
Vol
remove tensioning
ed b element.
y gu
ara
is nte
or
– Tightly holdaucompressor
th shaft with a spanner -1-. eo
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.
2. Compressor 267
– Opens clips for hose guides -2- and push hoses to one side.
– Carefully press locking lugs on noise insulation housing
-arrows- outwards.
AG. Volkswagen AG d
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nform
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at
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io
– Unscrew securing bolts -1- for supercharger and remove su‐
n
c
in t
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percharger together with intake silencer.

o
his
ate
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Removing intake silencer for charge air:

p
cum
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Prote AG.
– Pull intake silencer for charge air -2- together with pressure
pipe in direction of -arrow-.
Installing
Caution
When installing poly V-belts, observe direction of rotation and

make sure they are properly seated on pulleys and tensioning
elements.
Note
♦ Renew O-rings on pressure pipe ⇒ Item 7 (page 254) .

♦ Before installing, lightly moisten O-rings with engine oil.
♦ The pressure pipe can only be pushed in one position into the
intake silencer for charge air (note locating element).

lkswagen AG
AG. Vosupercharger)
ksw
agen does - Edition 08.2017
n
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– Push intake silencer for charge air -2- together ris with pressure
e
tee
ho
pipe in direction of -arrow- into intake connecting
aut pipe. or
ac
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– Press intake silencer for charge air -2- against crankcase to
ce
e
nl
pt
allow both dowel sleeves -3- to sit in holes.
du
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– Turn guide pins - T10341- hand-tight to stop in both lower
l purpos
threaded holes.
– Renew oil seal -1- and ensure it is correctly seated in the
nf
ercia
groove.
orm
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atio
– Push supercharger together with intake silencer onto guide
om
pins - T10341- and tighten upper securing bolts hand-tight.
n in
or c
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– Remove guide pins - T10341- .

t
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– Tighten lower securing bolts hand-tight.
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– Tighten securing bolts evenly and diagonally.
Co
Cop py
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agen
Prote AG.
– Install poly V-belt -3- for compressor along with belt pulley.
Specified torque for new securing bolt -2-: 40 Nm + 1/4 turn (90°)
further.
– Hold supercharger shaft with 16 mm spanner -1-.
– Install tensioner.
2. Compressor 269
– Tighten bolts -arrows- to 23 Nm.
– Hold tensioner using a 16 mm spanner and pull out pin -

T10060 A- .
– Position housing with noise insulation onto supercharger.
Note
Ensure correct position of noise insulation in housing.
satelettronica
– Press housing together with noise insulation against super‐
charger until locking lugs -arrows- click into place.
Perform further installation in reverse order, paying attention to
the following:
AG. Volkswagen AG d
agen oes
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au ra
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un
pt
♦ Renew securing bolt for supercharger pulley. Specified torque

an
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40 Nm + 1/4 turn (90°) further.

erm
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form
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Specified torques:
atio
om
n
c

i
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330
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270
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
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Golf 2004 ➤ ,y VGolf Plus 2005 ➤ , Tiguan 2008
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4-cylinder direct-injection engine (1.4risl, EA 111, turbocharger, supercharger) r-anEdition
ed
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ho
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– Push engine cover panel down at points
ss -1- in direction of c
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2.4 Removing and installing drive unit seal
nform
ercia
for supercharger
m
at
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ion
c
in t
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♦ Gearbox support - T10108-

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♦ Extractor hook - T20143-

n
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op py
♦ Repair kit for supercharger ⇒ Electronic parts catalogue (ET‐
. C rig
ht ht
rig
KA) py by
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Prote AG.
Note
All components in the repair kit must be used!
Removing
– Remove supercharger.
Engine codes BLG, BMY ⇒ page 255 .
Engine code BWK ⇒ page 263 .
– Secure compressor on the gearbox support - T10108- with 2
bolts-arrow-.
2. Compressor 271
– Pry off the circlip -1- with a slot-head screwdriver -2-.
– Pull out the seal -1- with the puller hooks - T20143/1- .
Installing
satelettronica
– Put together assembly cone -T10208/5- and assembly sleeve
-T10208/4- . agen
AG. Volkswagen AG d
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– Slide the new seal -1- onto the assembly sleeve in the d byV gu
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-arrow direction- -T10208/5- -T10208/4- via the assembly orise nte
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cone. aut
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– Pull down the assembly cone - T10208/5- from the assembly
sleeve in the -arrow direction- -T10208/4- .
rrectness of i
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r
te o
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

– Slide the assembly sleeve - T10208/4- onto the compressor

shaft.
– Using the thrust piece - T10208/2- , press in the seal via the
assembly sleeve - T10208/4- up to the stop.
satelettronica
– Press in the new circlip n A-1- up
G. Vo toagthe
lksw en Astop
G do also using the as‐
wage
sembly tool -y VT10208/2-
olks . es n
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Changinghothe
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t or
au ac
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– Undo the securing bolts for the drive unit according to the
specified sequence -A- to -H-.
rrectne
– Turn the gearbox support - T10108- until the shaft points to

the floor.
ss o
cial p
f inform
mer
atio
om
n
c
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Cop py
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Prote AG.
2. Compressor 273
– Unscrew the securing bolts and remove the drive unit -1-.
n AG. Volkswagen A
– Drain compressor ooil
lkswcompletely from drive unit.
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– Collect the escaping
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ed fluid in a suitable container. nte
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– Turn the
ss
agearbox support - T10108- until the pair of gears point
u ra
c
upwards.
ce
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pt
an
– Remove sealant residues from compressor and drive unit with
d
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a rotating brush, e.g. a hand drill with a plastic brush (wear eye
erm
ab
protection).
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– Carefully clean sealing surfaces. They must be free of oil and
h re
ole,
grease.
spec
– Dirt and sealant residues must not be allowed to enter the
t to the co
space.
rrectne
Caution
Add only the oil specified in repair set ⇒ Electronic parts cat‐
ss o
alogue (ETKA) .
cial p
f inform
mer
satelettronica
atio
om
– Fill the space -arrow- with new oil (44 ml) from the repair set.
n
c
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Note
um
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t.
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Sealant must not be applied too thickly, otherwise excess sealant Cop py
. rig
may enter the space and cause damage.
t
gh ht
pyri by
Vo
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cted agen
Do not apply sealant until directly before the drive unit is fitted. Prote AG.
– Apply sealant to the sealing surface on the compressor.
Bead of sealant must be 2 to 3 mm thick and must run along inside

edge in area of bolt holes.
– Tighten the new securing bolts for the drive unit to “12 Nm”
according to the specified sequence -A- to -H-.
– Install supercharger.
Engine codes BLG, BMY ⇒ page 255 .
Engine code BWK ⇒ page 263 .

3 Charge air system
Note
♦ It is recommended that the spring-type clips should be in‐

stalled using the spring-type clip pliers - VAS 5024A- or the
hose clip pliers - VAS 6340- .
free of oil and grease before assembly. The seals and sealing
surfaces must be oiled lightly for plug-in connectors ⇒ page
276 .
♦ Charge air system must be free of leaks.

satelettronica
Checking charge air system for leaks ⇒ page 277
Removing and installing charge air cooler (Golf, Golf Plus,
Touran) ⇒ page 281
Removing and installing charge air cooler (Tiguan) ⇒ page
283
3.1 Assembly overview - charge air system

AG. Volkswagen AG d
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erm
ab
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t to the co
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cial p
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mer
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c
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or
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Prote AG.
3. Charge air system 275

1 - Intercooler
(Golf, Golf Plus, Touran)
⇒ page 281
(Tiguan) ⇒ page 283
2 - 5 Nm
3 - Bearings
❑ For charge air cooler.
4 - Seal
5 - Charge air hose
6 - Intake manifold connection
❑ With seals.
7 - Throttle valve module - gen AG. Volkswagen AG d
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❑ Cleaning ⇒risepage 302
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❑ If renewed,ut erase learnt ra
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values and adapt en‐
s
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gine control unit - J623-

un
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⇒ Vehicle diagnostic
d
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tester “Guided func‐

erm
ab
tions”.
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8 - 7 Nm
h re
ole,
spec
9 - Hose clamp
t to the co
10 - Charge air hose

11 - 10 Nm
rrectne
12 - Charge air pipe

13 - Charge air pressure
ss
sender - G31- with intake air

o
cial p
f i
temperature sender 2 - G299-

nform
mer
14 - 5 Nm
atio
om

c
i
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❑ To turbocharger
t
sd
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16 - Charge air pipe

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Co
Cop py
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3.2 Fitting hose connections with plug-in
Prote AG.
connectors
Caution
The seal for the push-on coupling can be damaged if the re‐
taining clip is in the locked position during installation. This
would result in leaking. Observe installation instructions.
Removing:

– Release plug-in connector by pulling out retaining clip

-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose. AMake
G. Volksure
swagen AG
that the seal is correctly seated in the groove agen does
olkswall around the not
complete circumference and that it isenot by Vtwisted. gu
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– Lubricate sealing surface and seal
au with oil.
th eo
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ss c
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nl
pt
du
an
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erm
ab
ility
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– Bring retaining clip to release position -1-.
h re
hole
spec
– Push charge air hose into coupling to stop.
es, in part or in w
t to the co
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if plug-in connector seats correctly and is properly en‐
rrectness of i
gaged by pulling hose.
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote
3.3 Checking charge air system for leaks
AG.

♦ Charge air system tester - V.A.G 1687-

lkswage es n
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tho
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pt
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ab
ility
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, is n
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hole
spec
♦ Engine bung set - VAS 6122- (not shown)
es, in part or in w
t to the co
off.
rrectness of i
l purpos
rection of -arrow-.
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
. rig
t
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Vo
co
by lksw
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Prote
rection of -arrow-.
AG.
– Press hose locking mechanism and pull hose for crankcase

breather -1- off intake connecting pipe.
– Also pull crankcase breather hose off valve timing housing.
Caution
Crankcase breather hose must be pulled off during leak test to

prevent damage to engine.
– Seal intake connecting pipe with a bung from engine bung set
- VAS 6122- .
– Remove spring-type clips -2- from intake hose and remove
intake hose.

– Renew spring-type clips -arrows- with screw-type clips from

charge air system tester - V.A.G 1687- .
– Slide adapter - V.A.G 1687/6- into intake hose -2- and secure
hose to intake connecting pipe with screw-type clips -1- from
charge air system tester - V.A.G 1687- .
Prepare charge air system tester - V.A.G 1687- as follows:
satelettronica
– Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
AG. Volkswagen AG d
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d by ara
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aut ra
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un
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an
d
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erm
– Connect charge air system tester - V.A.G 1687- as shown.

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

– Connect pressure hose -1- (compressed air supply) to charge

air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high this can cause damage to the engine. gen AG. Volkswagen AG d
wa oes
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– Open valve -4- and wait untilthothe test circuit is filled. If neces‐ eo
u
sary readjust pressure to s0.5
s a bar.
ra
c
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– Check the charge air system for leaks by hearing, touching,

un
pt
an
d
with commercially available leak detector spray or using ultra‐
satelettronica
itte
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sonic tester - V.A.G 1842- .
rm
ab
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ility
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Note
spec
es, in part or in w
t to the co
♦ Slight leaks in the area of the intake connecting pipe
-arrows- are permissible, as the intake hoses are not designed
for high-pressure.
rrectness of i
♦ A small amount of air escapes through the valves and enters
l purpos
the engine. Therefore a holding pressure test is not possible.

♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
nform
ercia
instructions
m
♦ Depressurise test circuit by detaching coupling from adapter -

com
tio
V.A.G 1687/6- before removing adapter.

n in
r
te o
thi
♦ Hose connections and hoses must be free of oil and grease

s
iva
do
before assembly.
r
rp
cum
fo
en
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♦ After testing compression, secure intake hoses again with

n
t.
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spring-type clips. Cop py
ht. rig
rig ht
py by
o Vo
Engine cover panel ► November 2006 by c lksw
cted agen
Prote AG.
Note

AG. Volkswagen AG d
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olksw not
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d by ara
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Golf 2004au➤ t , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran r a2003 ➤
c
s
s l, EA 111, turbocharger, supercharger) - Edition 08.2017
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
or
m
m
atio
om
n in
or c
thi
te
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t.
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Cop py
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satelettronica
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran)


equipment required
satelettronica
lkswage es n
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byV ua
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tho
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erm
ab
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Removing
nf
ercia

rm
m
atio

om
sition .
n in
or c
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cu
– Pull coolant hoses off radiator.

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Cop py
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– Remove radiator securing bolts and remove radiator with fan yri
p by
o Vo
downwards.
c by lksw
cted agen
Prote AG.
Note


– Remove securing bolts -arrows-.

– Remove securing bolts from side bearing.
– Remove charge air cooler downwards.
Installing
Installation is carried out in the reverse order.
AG. Volksw When installing,
agen AG
note the following: agen does
olksw not
V y gu
db ara
Filling with new ocoolant
ris
e ⇒ page 136 . nte
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Specified torques:
ss
a c
ce
e
nl
pt
Component Nm
du
an
itte
y li
erm
ab
ility
ot p
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, is n
Charge air cooler to condenser 5
h re
hole
spec
es, in part or in w
3.5 Removing and installing charge air cooler, Tiguan
t to the co
satelettronica
rrectness of i
equipment required
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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o
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f
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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.


Removing
– Remove bracket -1- by unscrewing securing bolts -arrows-.
satelettronica
– Also remove second hose from charge air cooler.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
an
d
itte
– Disconnect connector -1-.

y li
rm
ab
pe
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

wal,geEA 111, turbocharger,
e supercharger) - Edition 08.2017
ks s no
Vol t gu
by ara
– Release retaining clip and pullrisconnection
ed
-arrow- off radiator. nte
utho eo
– Also pull off connection at
ss bottom of radiator.
a ra
c
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un
pt
an
d
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sition .
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
– Unscrew securing bolts -arrows- and remove cowling upwards
together with radiator fan - V7- .
l purpos
nform
ercia
Note
m
a
com
tio
The radiator fan - V7- and the cowling may only be renewed com‐
n in
plete.
r
te o
thi
satelettronica
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove securing bolt -arrow-. cted agen
Prote AG.
– Unscrew bolts -arrows- and remove radiator downwards.

– Remove securing bolts -arrows-.

– Remove securing bolts from side bearing.
– Remove charge air cooler downwards.
Installing
note the following:
Filling with new coolant ⇒ page 136 .
Specified torques: agen
AG. Volkswagen AG d
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yV gu
Component ised Nm
b ara
nte
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Cowling to radiator s aut 5 ra
c
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pt
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Charge air cooler to condenser 5
d
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ab
ility
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is n
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t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
sd
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pr
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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.

lkswage es n
o ot g
byV ua
ed ran
hoGolf
ris 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008
tee ➤ , Touran 2003 ➤
t or
4-cylinder direct-injection auengine (1.4 l, EA 111, turbocharger, supercharger) ac - Edition 08.2017
ss
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le
un
pt
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24 – Mixture preparation - injection
itte
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1 Injection system
h re
hole
spec
Assembly overview - parts l and II, intake manifold ⇒ page
es, in part or in w
287 .
t to the co
Assembly overview - fuel rail with injectors ⇒ page 292 .
rrectness of i
Checking vacuum reservoir for leaks ⇒ page 294 .
l purpos
Assembly overview - air filter ⇒ page 296 .

Removing and installing air filter ⇒ page 297 .
nform
ercia
Removing and installing regulating flap control unit - J808- and

m
a
throttle valve module - J338- ⇒ page 298 .
com
tion in
Cleaning throttle valve module - J338- ⇒ page 302 .
r
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s
iva
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Assembly overview - high-pressure pump ⇒ page 302 .
r
rp
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Checking fuel pressure in high-pressure section ⇒ page 303 .
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satelettronica
Removing and installing high-pressure pump ⇒ page 307
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Removing and installing injectors ⇒ page 311 . cop Vo
by lksw
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Renewing Teflon seal and support washer on injector ⇒ page
314
Safety precautions ⇒ page 317 .
Comply with rules for cleanliness ⇒ page 180 .
Technical data ⇒ page 319 .
General notes on injection
♦ The engine control unit - J623- is capable of self-diagnosis.
Before carrying out repairs and fault finding, read fault mem‐
ory. Also the vacuum hoses and connections must be checked
(unmetered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of crimp-type or screw-type clips is
not permissible.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the danger of a fire in a crash as the fuel pump is switched off
via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel
pump is activated for 2 seconds to build up pressure in the fuel
system.
1.1 Assembly overview - parts l and II, in‐

take manifold
Assembly overview - part II, intake manifold ⇒ page 290 .
1. Injection system 287

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1.2 Assembly overview - part I, intake manifold

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288 Rep. gr.24 - Mixture preparation - injection

1 - Intake air temperature

sender 3 - G520- with intake
manifold pressure sender 3 -
G583-
2 - 3 Nm
3 - 7 Nm
a power-operated
500 rpm and a max.
specified torque of 7 Nm
is set.
4 - Intake connecting pipe
5 - Seal
❑ Renew
6 - Regulating flap control unit
satelettronica
- J808-
⇒ page 298
❑ If renewed, erase learnt
values and adapt en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester “Guided func‐
tions”.
7 - 7 Nm
❑ The securing bolt mayn AG. Volkswagen A
only be tightened olks
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th or
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ss c
8 - Intake connecting pipe
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9 - Intake manifold connection

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10 - 7 Nm
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❑ The securing bolt may only be tightened using a power-operated screwdriver if the screwdriver speed is
spec
max. 500 rpm and a max. specified torque of 7 Nm is set.

t to the co
11 - 3 Nm
12 - Intake manifold pressure sender - G71-
rrectne
13 - O-ring
❑ Renew
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14 - Intake manifold
inform
mer
❑ To remove: Removing and installing regulating flap control unit - J808- and throttle valve module - J338-
atio
⇒ page 298 .
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15 - 20 Nm
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16 - Fuel pressure sender - G247- , 22 Nm

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❑ Checking fuel pressure in high-pressure section ⇒ page 303 .

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17 - 80 Nm C py
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18 - Intake manifold lower part

❑ To remove and install: use Holder for 5/16 inch bits - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 290
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 298 .
❑ On renewal, erase learnt values and adapt intake manifold flap potentiometer - G336- to engine control
unit - J623- ⇒ Vehicle diagnostic tester “Guided function”.
❑ Before removing and installing, lock vacuum actuator using a 2.5 mm drill bit.
❑ After installing a new lower part of intake manifold, remove retaining clip for vacuum positioning element.
❑ After installing, check function of intake manifold flap using hand-operated vacuum pump - VAS 6213-
19 - Seal
❑ Renew
❑ Observe installation position olkswage es n
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20 - 2.2 Nm ir se
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21 - Intake manifold flap potentiometer - G336- ss
au ac
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
ce
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un
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functions”.
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22 - 2.2 Nm
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23 - Vacuum actuator
wit
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❑ For intake manifold flap
ole,
spec
❑ Checking ⇒ page 294
t to the co
24 - 20 Nm
25 - Throttle valve module - J338-
rrectne
❑ Cleaning ⇒ page 302
ss o
❑ If renewed, erase learnt values and adapt engine control unit - J623- ⇒ Vehicle diagnostic tester “Guided
cial p
f in
functions”.
form
mer
26 - 7 Nm
atio
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n
c
27 - Pressure pipe
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❑ Before installing, lightly coat seal with clean engine oil.
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❑ From turbocharger
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28 - Retaining clip
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29 - 7 Nm
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Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
1.3 Assembly overview - part II, intake manifold

1 - Union
2 - Fuel hose
clips
3 - Connecting pipe
4 - Fuel hose
❑ Low pressure
❑ To high-pressure pump olkswage es n
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5 - Clamp ir se
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6 - Connection hose ss
au ac
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an
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8 - Connection hose
spec
es, in part or in w
9 - To pressure pipe.
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10 - Connecting pipe
rrectness of i
11 - Connection hose
❑ To intake manifold con‐
l purpos
nection.
12 - 8 Nm
nform
mercia
13 - Fuel line at
om
io
❑ High pressure
n
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❑ Specified torque for

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union nuts: 18 Nm.

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14 - Union
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❑ To intake connecting pipe. C py
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15 - Connection hose cop Vo
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16 - Non-return valve
AG.
❑ For crankcase ventilation.

18 - Charge pressure control solenoid valve - N75-
❑ To turbocharger
21 - Union
22 - 5 Nm
❑ To turbocharger
24 - Union
25 - Union

❑ To charge pressure control solenoid valve - N75- .
28 - Union
❑ For crankcase ventilation. en AG. Volkswagen AG
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❑ Connected to valvey timing not
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29 - Vacuum hose horis nte
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❑ From vacuum au reservoir ac
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30 - Vacuum hose
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❑ To vacuum positioning element
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31 - Vacuum hose
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❑ To intake manifold flap valve - N316-
h re
ole,
spec
32 - Vacuum hose
t to the co
33 - Non-return valve
satelettronica
❑ Ensure correct installation position before installing
rrectne
Note
ss o
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♦ The valve is one-directional.
nform
mer
♦ Wrong position may result in

atio
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complaints about driving be‐

o
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haviour.
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34 - Intake manifold flap air flow control valve - N316-

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35 - Union
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❑ For vacuum hoses.
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36 - Union
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37 - Vacuum hose
38 - Fuel hose
❑ To lower part of intake manifold
❑ For fuel return line.
1.4 Assembly overview - fuel rail with injectors

1 - O-ring
❑ Renew
❑ Before installing, moist‐
en lightly with clean en‐
gine oil.
2 - Spring element
❑ Renew each time after
removing lower part of
intake manifold.
❑ Ensure proper seating
on injector.
3 - Injector, cylinder 4 - N33-
❑ Injector, cylinder 1 -
N30- AG. Volkswagen AG d
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❑ Injector, cylinder Volksw2 - not
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N31- sed b ara
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❑ Injector,
autho
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N32-
ss c
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❑ With Teflon seal and

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d
support washer.
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❑ After removing injector,
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Teflon seal and support

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washer must be re‐

newed ⇒ page 314 . h re
ole,
spec
❑ Removing and installing t to the co

injectors ⇒ page 311 .
4 - Vacuum hose
rrectne
5 - Return line
❑ From high-pressure
s
pump.
s o
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❑ Blue or with blue mark‐

inform
ing
mer
atio

om
clips
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6 - 20 Nm
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7 - Pressure limiting valve
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❑ Before installing lightly moisten O-rings with clean engine oil.

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❑ Press in by hand using an 8 mm hexagon key.
8 - Intake manifold lower part
❑ To remove and install: use Holder for 5/16 inch bits - V.A.G 1766/2- and Bit - 3320/2- ⇒ page 294
❑ To remove, removing and installing regulating flap control unit - J808- , throttle valve module - J338- and
intake manifold ⇒ page 298 .

Removing and installing lower part of intake manifold

To remove and install securing bolt -arrow-, use holder for bits
with 5/16'' drive - V.A.G 1766/2- and special wrench, long reach
- 3320/2- .
Checking function of intake manifold flap

– After installing a new lower part of intake manifold, remove
retaining clip -arrow- for vacuum positioning element.
– Connect hand vacuum pump - VAS 6213- as shown in illus‐
tration.
– Generate a vacuum, and check function of vacuum unit on
lever arm.
satelettronica
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When the intake manifoldrisisedremoved, the function of intake man‐arant
b
ifold flap can be checkedut
h simultaneously.
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1.5 Checking vacuum reservoir for leaks

an
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es, in part or in w
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Test conditions
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Perform visual check if all vacuum hoses on intake manifold are

o
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not damaged and connected properly.

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Test sequence
t. C rig
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Vacuum reservoir is integrated into engine cover panel.
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– Pull vacuum hose -arrow- off vacuum reservoir.

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– Connect hand vacuum pump - VAS 6213- to connection.
t to the co
– Screw in knurled screw on hand vacuum pump - VAS 6213- .
rrectness of i
– Operate hand vacuum pump until a vacuum of 0.3 bar is at‐
tained on pressure gauge.
l purpos
satelettronica
Note
nf
ercia
orm
m
atio
Due to the high volume in the vacuum reservoir, 20 strokes may
om
be necessary to generate a pressure of 0.3 bar.
n in
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– Observe pressure approx. 3-5 minutes.

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If pressure of 0.3 bar is displayed:

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Vacuum reservoir is OK.
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If pressure drops:
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– Renew engine cover panel with vacuum reservoir.
Note



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1.6 Assembly overview - air filter ab

ility
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Removing and installing air filter ⇒ page 297 . h re

ole,
spec
t to the co
rrectness o
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f inform
mer
atio
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1 - 1.6 Nm
2 - Air filter upper part agen
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un
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connection and vacuum
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hose, do not use sharp- rm
ab
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edged tools to remove
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the hose.
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spec
es, in part or in w
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❑ From camshaft housing.
4 - Spring-type clip
rrectness of i
ing spring-type clip pli‐
l purpos
ers - VAS 5024A- .

5 - Intake hose
nform
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satelettronica
6 - Cover
m
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7 - Intake air guide
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8 - Air filter lower part
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❑ With captive securing
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❑ Specified torque: 8Nm
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9 - Water drain hose Prote AG.
❑ When installing, arrows

on lower part of air filter
and water drainage
hose must align.
10 - O-ring
❑ Renew
11 - Filter element
1.7 Removing and installing air filter

Removing
– Pull coolant hose upwards out of brackets -arrows-.
– Press fastener -1- and pull intake air duct cover out upwards.

– Press fastener -arrows- and pull intake air duct upwards.

– Release spring-type clip -1- and pull intake hose off air filter.
– Loosen securing bolt -2- and pull air filter housing upwards
from locating pins -arrows-.
Installing
the following:
– Push air filter housing onto locating pins -arrows- from above.
satelettronica
AG. Volkswagen AG d
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– Tighten new securing bolt oris -2- to 8 Nm and slide spring-type
e nte
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clip -1- with intake hose
aut onto air filter connection.
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1.8 Removing and installing regulating flap

s
control unit - J808- and throttle valve

s o
cial p
module - J338-
inform
mer
atio
om
Note
c
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To remove throttle valve module - J338- , regulating flap control

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cum
unit - J808- must first be removed.

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Special tools and workshop equipment required t. C rig
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r
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Removing regulating flap control unit - J808-

s
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t.
– Release vacuum hose from vacuum reservoir -arrow- and pull
yi Co
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off. . C rig
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rection of -arrow-.
agen
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rection of -arrow-.
– Remove securing bolts -1-.

– Detach spring-type clips and pull off hose -2- on activated

charcoal filter system solenoid valve 1 - N80- and pressure
pipe -3-.
– Unscrew securing bolt for pressure pipe -3- on turbocharger
and pull pressure pipe -3- off.
– Pull off all connectors and hose connections on intake con‐

necting pipe -4- and regulating flap control unit - J808- .
satelettronica
– Unscrew intake connecting pipe securing bolts -arrows- and
pull intake connecting pipe upwards with regulating flap con‐
trol unit - J808- .
lkswage es n
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ility
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– Unscrew securing bolts -arrows-.

h re
hole
Removing throttle valve module - J338-

spec
es, in part or in w
t to the co
– Detach coolant hose -1- from hose clips.

rrectness of i
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nf
ercia
orm
m
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om
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– Pull connector -2- off intake air temperature sender 3 - G520-

with intake manifold pressure sender 3 - G583- .
– Remove charge air hose -3- from throttle valve module - J338-
and charge air pipe.
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nl
– Unscrew securing bolts -arrows- and pull throttle valve module
pt
du
an
itte
- J338- from intake manifold connection.
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Installing
ility
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note the following:
spec
es, in part or in w
♦ Always renew gaskets and seals.
t to the co
satelettronica
rrectness of i
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nform
ercia

m
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Note
at
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Specified torques:
If a new regulating flap control unit or throttle valve module has
been installed:
– Erase learnt values and adapt engine control unit - J623- to
regulating flap control unit and throttle valve module ⇒ Vehicle
diagnostic tester “Guided functions”.
1.9 Cleaning throttle valve module - J338-
Note
♦ If a new engine control unit - J623- is installed the throttle valve

module must be adapted. Adaptation must be performed only
with a new or cleaned throttle valve module, because soiling
satelettronica
or coking at the end stop of the throttle valve can lead to in‐
correct adaptation values.
wage es n
♦ When cleaning the throttle valve housing it must not ybe Volks ot g
scratched. ir se
d b ua
ran
o tee
th or
au ac
– Remove throttle valve module (engine codes ss BLG, BMY,
BWK) ⇒ page 298 .
ce
e
nl
pt
du
an
itte
– Open throttle valve by hand and lock in open position using a
y li
erm
ab
suitable object (e.g. wood or plastic wedge) -arrow-.
ility
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WARNING
hole
spec
es, in part or in w
Acetone is highly inflammable. Please comply with the acci‐
t to the co
dent prevention regulations and the safety instructions when
handling highly inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear protective goggles and
rrectness of i
l purpos
nf
ercia
or
– Thoroughly clean throttle valve housing, especially around the

m
m
atio
closed throttle valve -arrows- using commercially available

om
n in
acetone according to DIN 53247 and a brush.

or c
thi
te
– Wipe off throttle valve housing using a lint-free cloth.

sd
iva
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rp
cu
– Allow acetone to evaporate completely and re-install throttle

o
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f
en
ng
valve module after cleaning.

t.
yi Co
Cop py
– Erase learnt values and adapt engine control unit - J623- to
t. rig
gh ht
yri by
throttle valve module ⇒ Vehicle diagnostic tester “Guided cop Vo
by lksw
functions”. cted agen
Prote AG.
1.10 Assembly overview - high-pressure

pump
WARNING


6 bar).
prox. 6 bar. The appropriate procedure is described in the
chapter on releasing pressure in the high-pressure section ⇒
page 158 .
1 - Roller tappet
❑ Lightly coat with engine
oil when installing. AG. Volkswagen AG d
agen oes
ksw
2 - O-ring by Vol not
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ara
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❑ Renew rise nte
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❑ Lightly coat swith
s a engine
ra
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oil when installing.
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pt
satelettronica
an
d
3 - High-pressure pump with

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fuel pressure regulating valve -
rm
ab
pe
ility
N276-
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h re
hole
Caution
spec
es, in part or in w
Only grasp high-pres‐
t to the co
sure pump on housing
when removing and in‐
stalling!
rrectness of i
When the high-pressure
l purpos
piston spring package

loosens the high-pres‐
nform
sure pump will leak and

ercia
must be replaced.
m
a
com
tion in
r
te o
4 - 8 Nm
thi
s
iva
do
5 - Union
r
rp
cum
fo
❑ High pressure
en
ng
t.
yi Co
op py
6 - Union nut, 18 Nm t. C rig
gh ht
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❑ Observe safety precau‐ cop Vo
by lksw
tions ⇒ page 158 . Prote
cted AG.
agen
❑ Counterhold when loos‐

ening connection to
high-pressure pump.
7 - Fuel hose
❑ Low pressure
❑ With spring-type clip.
8 - Union
❑ Low pressure
1.11 Checking fuel pressure in high-pressure

section

♦ Double hex socket 1/2”, 27mm - VAS 5301/7- AG. Volkswagen AG d

agen oes
olksw not
yV gu
♦ Digital pressure gauge - VAS 6394/1- ised b ara
nte
or eo
h
♦ Test adapter - VAS 5570- s aut ra
c
s
ce
e
nl
pt
du
WARNING
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
6 bar).
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
page 158 .
nf
ercia
o
Procedure
rm
m
atio
m
– Remove engine cover.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
off. m
f
en
ng
t.
yi Co
op
– Lift engine cover panel at points -1- and pull it forwards in di‐ C py
ht. rig
rection of -arrow-. rig ht
py by
co Vo
by lksw
Engine cover panel, November 2006 ► Prote
cted AG.
agen


– Lift engine cover panel at points -1- and pullnitAG
forwards
. Volkswagin di‐
en AG do
rection of -arrow-. wage es n
olks o V t gu
by ara
– Remove air filter ⇒ page 297 .rised nte
tho eo
s au ra
c
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
– Remove fuel pressure sender - G247- -1-.
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Instead of fuel pressure sender - G247- , screw in adapter -
en
ng
t.
yi
VAS 6394/2- and tighten to 22 Nm.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open cover -2- of digital pressure gauge - VAS 6394/1- and

tighten fuel pressure sender - G247- to digital pressure gauge
to 22 Nm.
– Screw pressure line -1- of digital pressure gauge - VAS
6394/1- hand-tight to adapter - VAS 6394/2- .

– Connect test adapter - VAS 5570- between fuel pressure

sender - G247- -1- and connector.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
– Connect vehicle diagnostic tester -1- as follows:
hole
spec
– Push diagnostic cable connector -2- onto diagnostic connec‐
es, in part or in w
t to the co
tion in driver footwell.
rrectness of i
– Press following keys on display in succession:
l purpos
Vehicle self-diagnosis
satelettronica
Vehicle self-diagnosis
nform
mercia
01 - Engine electronics
a
com
tion in
011 - Measured values
r
te o
thi
– There, enter 248 and acknowledge with Q .

s
iva
do
r
rp
cum
fo
Display field 2 shows the nominal value; display field 3 shows the
en
ng
t.
actual value reported to the vehicle by the fuel pressure sender - op
yi Co
G247- .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Switch on digital pressure gauge - VAS 6394/1- by pressingProte
cted AG.
agen
key -A- briefly once.
Note
When button -A- is pressed for 2 seconds, the illumination will be

switched on for 20 seconds.
Digital pressure gauge - VAS 6394/1- should display 0 bar; if this

is not the case, press key -C- briefly once for zero point compen‐
sation.
– Start engine.
– Compare pressure displayed by digital pressure gauge - VAS
6394/1- with actual value of vehicle diagnostic tester .
The pressure values may deviate from each other by up to 5 bar.
If pressures do not correspond, fuel pressure sender - G247-
must be renewed.

AG. Volkswagen AG d
agen oes
ksw not
WARNING by Vol
gu
ara
d
rise nte
o eo
Digital pressure gauge - VAS 6394/1- is subject aut to high fuel
h
ra
pressure! Whilst engine is running, pull off connector
ss
from fuel c
ce
le
pressure regulating valve - N276- . This reduces fuel pressure
un
pt
to approx. 6 bar. Switch off ignition. Place a cleaning cloth
an
d
itte
y li
around fuel pressure sender - G247- , then reduce residual
rm
ab
pressure by carefully loosening fuel pressure sender - G247- .
pe
ility
ot
wit
, is n
h re
hole
spec
Note es, in part or in w
t to the co
♦ When the engine is idling and the electrical connector is pulled
off the fuel pressure regulating valve - N276- , the pressure in
rrectness of i
the high-pressure system will drop to approx. 6 bar.
l purpos
♦ Once the high-pressure in the high-pressure area is reduced,

open the system immediately as the pressure will rise again
nform
ercia
due to warming.
m
a
com
ti
– Renew fuel pressure sender - G247- and again compare both
satelettronica
n in
measured values.
r
te o
thi
s
iva
do
If measured values again fail to correspond:
r
rp
cum
fo
– Check wiring ⇒ Vehicle diagnostic tester.
en
ng
t.
yi Co
op
If measured values correspond:
C py
t. rig
gh ht
yri by
– Further testing is carried out with “Guided Fault Finding” in cop Vo
by lksw
cted
⇒ Vehicle diagnostic tester.
agen
Prote AG.
1.12 Removing and installing high-pressure

pump

AG. Volkswagen AG d
agen oes
ksw not
Golf 2004 ➤ , Golf Plus by V 2005 ➤ , Tiguan 2008 ➤ , Touran
ol
gu
ara
2003 ➤
d
rise engine (1.4 l, EA 111, turbocharger,
nte supercharger) - Edition 08.2017
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
t to the co
rrectness o
Condition
cial p
f inform
• Engine must be cold.
mer
atio
m
Removing
o
n
c
i
or
n thi
te
sd
iva
o
r
Comply with rules for cleanliness ⇒ page 180

p
cum
r
fo
en
satelettronica
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING cop Vo
by lksw
cted agen
Prote AG.
6 bar).
page 158 .
– Separate fuel supply line -arrow-.

– Pull connector and fuel supply line -arrows- off high-pressure

pump.
Note
Catch escaping fuel in a cloth.
– Remove wiring guide -2- and take clip -4- off high-pressure
line.
Note
Use a spanner to counterhold threaded connections on high pres‐

sure pump and on lower part of intake manifold when loosening
union nuts.
satelettronica
n AG. Volkswagen A G do
wage es n
Volks ot g
y ua
db ran
ise
rCaution tee
tho
or
au ac
ss
Only grasp high-pressure pump on housing when removing
ce
le
un
pt
and installing!
an
d
itte
y li
rm
When the high-pressure piston spring package loosens the

ab
pe
ility
high-pressure pump will leak and must be replaced.

ot
wit
, is n
h re
hole
spec
– Loosen union nuts -3- and -1- of high-pressure line.

es, in part or in w
t to the co
– Remove securing bolts -1-, -2- and -3- equally.

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.

– Pull high-pressure pump -3- and roller tappet -1- out of

camshaft housing.
Installing
note the following:
Note
♦ Moisten high-pressure pump roller tappet with clean engine

oil.
♦ The high-pressure pump O-ring must always be renewed.
– Slide roller tappet -1- into camshaft housing.
– Insert new, lubricated O-ring -2- in groove of high-pressure
satelettronica
pump -3-.
– Place high-pressure pump -3- onto camshaft housing.
– Tighten securing bolts -1-, -2- and -3- equally.
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
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.

– Tighten union nuts of high-pressure line -1- and -3- hand-tight.

– Install wiring guide -2- and fit clip -4- on high-pressure line.
Specified torque of wiring guide securing bolt: 8 Nm
Note
Use a spanner to counterhold threaded connections on high-

pressure pump and on lower part of intake manifold when tight‐
ening union nuts.
– Tighten union nut -1- of high-pressure line to 18 Nm.

– Tighten union nut -3- of high-pressure
gen AG
. Volkswagline
en AGto 18 Nm.
d a oes
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
satelettronica
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Secure fuel supply line and connector -arrows- on high-pres‐

t to the co
sure pump. rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
– Reconnect fuel supply line -arrow-.

en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.13 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 317 .
Note

Teflon seal on injector must be renewed each time after removing

injector ⇒ page 314 .

♦ Tool set - T10133-
satelettronica
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
Removing
ot p
wit
is n
Remove air filter ⇒ page 297 .

h re
ole,
spec
Remove regulating flap control unit - J808- and throttle valve


t to the co
– Remove intake manifold and lower part of intake manifold ⇒

page 288 .
rrectnes
Note
s o
cial p
f in
Before removing, lock vacuum actuator using a 2.5 mm drill bit.

form
mer
atio
m
– Press the O-ring upwards by hand as shown, and remove it

o
n
c
i
or
from the injector.

thi
te
sd
va
– Screw slide hammer - T10133/3- to puller - T10133/15- .

i
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.

– Then insert puller - T10133/15- into groove -arrow- on injector.
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
– Pull injector out by tapping carefully.
l purpos
satelettronica
Installing
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
– Thoroughly clean injector holes in cylinder head using nylon
Prote AG.
brush - T10133/4- .
– Check plastic support washer for damage, renew if necessary
⇒ page 314 .
– Renew spring element -arrow- and Teflon seal each time the
injectors are removed ⇒ page 314 .
– Renew O-rings between injector and lower part of intake man‐
ifold and moisten slightly with clean engine oil.
Note
The Teflon seal on the injector must not be oiled or greased.
– Push injector into cylinder head bore to stop by hand.
Note

The injector must insert easily. If necessary wait until the seal has AG. Volkswagen AG d
contracted sufficiently. agen oes
olksw not
V gu
d by ara
ise nte
r
– Ensure correct position of injectors in cylinder head. ut ho eo
ra
s a c
– Place lower part of intake manifold carefully on injectors and s
ce
le
tighten securing bolts to 20 Nm ⇒ page 288 .
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ Before installation, lock vacuum actuator using a 2.5 mm drill
hole
spec
bit.
es, in part or in w
t to the co
♦ After installation of lower part of intake manifold, remove
2.5 mm drill bit.
rrectness of i
– Install intake manifold ⇒ page 288 .
l purpos
– Install regulating flap control unit - J808- and throttle valve

nform
ercia
Install air filter ⇒ page 297 .
satelettronica
m
a
com
tion in
1.14 Renewing Teflon seal and support
r
te o
thi
washer on injector
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
♦ Tool set - T10133- C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure
Renewing Teflon seal
Remove air filter ⇒ page 297 .
Remove regulating flap control unit - J808- and throttle valve
– Remove intake manifold and lower part of intake manifold ⇒
page 288 .
Note
Before removing, lock vacuum actuator using a 2.5 mm drill bit.
– Remove injectors ⇒ page 311 .

– Clean injector carefully.
– Carefully cut open seal with a knife as shown -arrow-. Avoid
contact between knife blade and valve body under all circum‐
stances.

. Volkswagen AG
4-cylinder direct-injection engine (1.4 l, EA 111,w gen AG
aturbocharger, supercharger)
does - Edition 08.2017
olks no
yV t gu
db ara
– Remove old seal and clean seal groove r se area
iin of seal nte
tho eo
-arrow-. Remove coking deposits using
s au a brass wire brush. ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
assembly sleeve - T10133/6- (knurled end faces seal -1-),
ss
gently slide seal onto assembly cone - T10133/5- as far as
o
cial p
f
possible.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
satelettronica
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
– Turn assembly sleeve - T10133/6- around (knurl no longer Prote AG.
points to seal), and push seal -1- as far as stop onto assembly
cone - T10133/5- .
– Now place assembly cone - T10133/5- with seal onto injector
from front. Slide seal further onto injector using assembly
sleeve - T10133/6- .
The seal is not yet seated in its groove.

– Remove assembly sleeve - T10133/6- and assembly cone -
T10133/5- .
– Slide seal into annular groove by hand.
– Position spacer sleeve - T10133/11- onto valve body.
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

– Pull off calibrating sleeve - T10133/7- again.

– Now push calibrating sleeve - T10133/8- over seal to stop onto
spacer sleeve - T10133/11- .
– Pull off calibrating sleeve - T10133/8- again.
Now the Teflon seal has correct installation dimensions.

AG. Volkswagen A gen G do
swa es n
Renewing support washer
by
Vol
k ot g
ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove O-ring -3-.
– Cut support washer -2- open with a small pair of side cutters
rrectness of i
and remove it.

l purpos
– Pull spring element -1- off injector and replace with retaining
plate - T10133/12- .
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
op
– Place new support washer -1- onto assembly cone - C py
ht. rig
T10133/13- and position onto injector as shown. rig ht
py by
co Vo
by lksw
– Slide support washer -1- into first groove -arrow- on injector Prote
cted AG.
agen
using calibration sleeve - T10133/17- (knurled side points to
injector).

– Now turn calibration sleeve - T10133/17- around (knurled side

no longer points to injector). Slide calibration sleeve over sup‐
port washer -1- in direction of -arrow- to stop on retaining plate
. Volkswagen AG
- T10133/12- . sw agen AG does
k not
y Vol gu
– Pull calibrating sleeve s-eT10133/17-
db down again. ara
nte
ri
ho eo
The support washer now
au has correct installation
t dimensions. ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Now position a new spring element -1- for retaining plate -
es, in part or in w
T10133/12- and position a new O-ring -3- in front of support
t to the co
washer -2-.
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
The Teflon seal -arrow- must not be oiled to install injector. pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install injectors ⇒ page 311 .
– Place lower part of intake manifold carefully on injectors and
tighten securing bolts to 20 Nm ⇒ page 288 .
Note
♦ Before installation, lock vacuum actuator using a 2.5 mm drill

bit.
♦ After installation of lower part of intake manifold, remove
2.5 mm drill bit.
– Install intake manifold ⇒ page 288 .

– Install regulating flap control unit - J808- and throttle valve
Install air filter ⇒ page 297 .
Further installation is carried out in reverse order of removal.
1.15 Safety precautions
WARNING
Fuel system is under pressure! Wear protective goggles and



off connection.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
♦ For safety reasons, fuse No. 27 must be removed from fuse
holder on left under dash panel before opening fuel system.
Otherwise fuel pump will be activated by driver door contact
switch.
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed. AG. Volkswagen AG d
agen oes
ksw
♦ Switch off ignition before connecting or disconnecting injection by
Vol not
gu
ara
and ignition system wiring as well as test instrument cables.rised
nte
ho eo
aut ra
ss c
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
sitions.
t to the co
rrectness of i
l purpos
Note the following if testers and measuring instruments have to

be used during a road test:
nf
ercia
♦ Test and measuring instruments must always be secured to
orm
rear seat and operated by a second person from this location.
m
atio
om
n in
If test and measuring instruments are operated from front pas‐
or c
thi
senger seat and the vehicle is involved in an accident, there is a
te
sd
a
possibility that the person sitting in this seat may receive serious
iv
o
r
rp
cu
injuries when the airbag is triggered.
o
m
f
en
ng
t.
yi
♦ If the engine is to be turned at starter speed without starting:
Co
Cop py
t. rig
gh
– Pull all 4-pin connectors -arrows- off ignition coils.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– To do this, fit pullerg-eT10094

AG. VolksA-
waon
genignition
AG do coil with final output
a n
stage -arrow- V o⇒
l page
ksw 341 . es n
ot g
y u
db ara
– Slightly
or pull out ignition coil with output stage.
ise nte
e
th or
au
– Fitss assembly tool - T10118- as shown. ac
ce
e
nl
– Carefully release connector locking mechanism and pull off
pt
du
an
connector.
itte
y li
erm
ab
– When installing ignition coil for final output stage, slide con‐
ility
ot p
nector on until it audibly engages.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit puller - T10094 A- as shown ⇒ page 341 .
– Press ignition coil with final output stage into cylinder head in
rrectness of i
l purpos
nform
mercia
at
om
satelettronica
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
1.16 Rules for cleanliness
t. C rig
gh ht
pyri by
Vo
o
by c
When working on the fuel supply/injection system, carefully follow
lksw
cted agen
Prote
the “5 rules” below:
AG.
♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.
1.17 Technical data

Engine code BLG, BMY, BWK
Idling check
Idling speed12) rpm 630 … 780
Engine control unit - J623-
System Motronic MED
Governed speed rpm From approx. 5600-6000
12) Not adjustable.

2 Engine control unit - J623-

Removing and installing engine control unit - J623- (Golf) ⇒ page
320
Removing and installing anti-theft engine control unit - J623-
(Golf) ⇒ page 321
Removing and installing engine control unit - J623- (Golf Plus,
Touran) ⇒ page 323
Removing and installing anti-theft engine control unit (Golf Plus,
Touran) - J623- ⇒ page 324 .
Removing and installing engine control unit - J623- (Tiguan) ⇒
page 326
Removing and installing anti-theft engine control unit - J623-
(Tiguan) ⇒ page 328
2.1 Removing and installing engine control

unit - J623- (Golf)
If you wish to renew the engine control unit, connect the ⇒ Vehicle
satelettronica
diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
– Remove securing bolts -1- and remove cover plate -2-.
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– Release front connector -1- from engine control unit and pull
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it off.
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– Lever up catch -2- slightly.

es, in part or in w
t to the co
– Then press engine control unit out of retainer

-in direction of arrow-.
rrectness of i
– Then release rear connector on engine control unit and pull it

off.
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Installing
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– Fit rear connector to engine control unit and lock in position.

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– Push engine control unit onto bracket.

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– Fit front connector to engine control unit and lock it in position.

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– Install cover plate for connectors.

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Rep. gr.24 - Mixture preparation - injection

– If engine control unit - J623- is renewed, erase learnt values
and adapt engine control unit ⇒ Vehicle diagnostic tester
“Guided functions”.
– Install plenum chamber bulkhead ⇒ General body repairs;
– The readiness code must be generated if the fault memory has
been erased. wage
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– Read control
au unit fault memory again.
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2.2 Removing and installing anti-theft en‐
pt
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gine control unit - J623- (Golf)
erm
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♦ Hot air blower from wiring harness repair set - VAS 1978-
satelettronica
spec
t to the co
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♦ Nozzle attachment from wiring harness repair set - VAS 1978-

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diagnostic tester and carry out the guided function “Renew control C py
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Removing Prote
cted AG.
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– Remove wiper arms and plenum chamber cover: ⇒ Electrical
system; Rep. gr. 92 ; Windscreen wiper system; Removing
and installing windscreen wiper system .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat (scorching/
melting of plastics etc.).
2. Engine control unit J623 321

Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600°C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Insert a screwdriver between protective housing -A- and
satelettronica
bracket -arrow-.
. Volkswagen AG
– Lever up protective housing using screwdriver -A- and in side‐ kswagen AG does
wards motion pull off bracket -arrow-. by
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– Bend catch open slightly -1-.

rrectness of i
– Then push engine control unit out of retainer -arrow-.

l purpos
– Now release connector on engine control unit and pull off con‐
nector.
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Installing
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– Fit connector to engine control unit and lock connector in po‐

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sition.
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– Push engine control unit onto bracket.

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– Press catch -1- against engine control unit.

– Select “Guided functions” on vehicle diagnostic tester .
– Perform vehicle identification and select engine code.
– Perform function “Renew control unit”.
– Push protective housing onto bracket.
– Tighten new shear-head bolts -1- evenly until heads shear off.
satelettronica
been erased.
– Read control unit fault memory again.
2.3 Removing and installing engine control agen

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If you wish to renew the engine control unit, connect
ut
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the ⇒ Vehicle or
diagnostic tester and carry out the guided function
ss a “Renew control ac
unit”.
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Removing
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– Switch off ignition. ab

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– Remove plenum chamber bulkhead ⇒ General body repairs; h re

hole
spec
es, in part or in w
– Loosen securing bolts -arrows- of control unit cover.

t to the co
– Then remove securing nuts for control unit bracket -arrows-.

rrectness of i
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– Release connectors on engine control unit and pullss aoff con‐
u ra
c
nector.
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– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
nform
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Installing
m
at
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– Push engine control unit onto control unit bracket until it en‐
ion
c
gages in catches.
in t
or
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ate
– Fit connectors to engine control unit and lock in position.
do
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– Tighten securing bolts -arrows- to 10 Nm.

been erased.
– Read control unit fault memory again.

gine control unit - J623- (Golf Plus,
Touran)

♦ Hot air blower from wiring harness repair set - VAS 1978-
♦ Nozzle attachment from wiring harness repair set - VAS 1978-

diagnostic tester and carry out the guided function “Renew control
unit”.
Removing
satelettronica
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . agen
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The shear-head bolt threads are coated with locking compound.

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Heating the shear-head bolt with a hot air blower releases the
an
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locking effect of the locking compound.
erm
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ility
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Caution
hole
spec
es, in part or in w
Cover lines, connections and control units in the vicinity of the
t to the co
engine control unit to prevent damage through heat (scorching/
melting of plastics etc.).
rrectness of i
l purpos
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
nform
ercia
output (600°C).
m
– Set two-stage switch for volume of air -3- to position 3. at

om
ion
c
in t
or
his
e
WARNING
at
do
priv
cum
or
When shear-head bolts are heated up, parts of the protective

f
en
ng
t.
housing will be subjected to a large amount of heat. Wear pro‐
yi Co
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tective gloves to avoid possible injury.
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– Place nozzle of hot air blower close to shear-head bolt.
AG.
– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
onds.
– Unscrew shear-head bolt using mole grips on bolt head.
The procedure for the second shear-head bolt is identical.
– Then remove securing nuts for control unit bracket -arrows-.

– Release connectors on engine control unit and pull off con‐

nector.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
satelettronica
– Install cover of protective housing.
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– Tighten new shear-head bolts -arrows- evenly until heads

es, in part or in w
shear off.
t to the co

rrectness of i

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– Perform road test. C py
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– Read control unit fault memory again. op Vo
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2.5 Removing and installing engine control

unit - J623- (Tiguan)

AG. Volkswagen AG d
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If you wish to renew the engine control unit, connect olksthe vehicle
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diagnostic tester and perform the guided functioned “Renewing con‐
b ara
nte
trol unit”. ris
tho eo
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Removing ss
ce
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un
pt
an
d
itte
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erm
ab
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
ility
ot p
wit
is n
h re
terior; Rep. gr. 64 ; Removing and installing plenum chamber ole,
spec
cover
t to the co
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
rrectne
wards and pull off both connectors.
– Remove securing bolts -3-.
ss o
cial p
f
– Remove retainer frame with engine control unit from plenum
inform
chamber.
mer
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satelettronica
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– Press locking device -1- outwards and slide engine control unit
py by
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-2- in -direction of arrow-. Prote
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Installing
– Slide engine control unit -1- into retaining frame in

-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.


– Fit connectors to engine control unit and slide locking devices
-2- inwards.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 64 ; Removing and installing plenum chamber
cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

gine control unit - J623- (Tiguan)
If you wish to renew the engine control unit, connect the vehicle
diagnostic tester and perform the guided function “Renewing con‐
trol unit”.
satelettronica
♦ Grip pliers
Removing AG. Volkswagen AG d
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– Switch off ignition. by Vo gu
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– Remove wiper arms ⇒ Electrical system; Rep.utho gr. 92 ; Wind‐ eo
ra
screen wiper system; Removing and installing
ss a wiper arms . c
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un
pt
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terior; Rep. gr. 64 ; Removing and installing plenum chamber

itte
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cover
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– Unscrew bolts -1-.
wit
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– Cover the plenum chamber with a clean cloth so that it is not
hole
spec
scratched.
es, in part or in w
t to the co
– Raise engine control unit with retaining frame slightly.
– Release engine control unit in direction of -arrow- and pull out
slightly. rrectness of i
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nform
mercia
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tion in
– Bend the upper ends -1- of locking clip outwards.

r
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– Remove shear-head bolts -2- using grip pliers and remove

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locking clip.
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– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
– Remove engine control unit.
Installing:
– Slide engine control unit -1- in direction of -arrow- in retaining

frame until it engages.
– Tighten the retaining frame.
satelettronica
– Fit connectors to engine control unit and slide locking devices
-1- inwards.
– Take a new locking clip and tighten new shear-head bolts
evenly until heads shear off. wage
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26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ After working on the exhaust system, ensure that the system

is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
Assembly overview - catalytic converter and attachments (engine

codes BLG, BMY) ⇒ page 330
satelettronica
Assembly overview - catalytic converter and attachments (engine
code BWK) ⇒ page 332
Assembly overview - silencer with mountings (engine codes BLG,
BMY) ⇒ page 333
Assembly overview - silencer with mountings (engine code BWK)
⇒ page 334
Removing and installing front exhaust pipe (engine code BWK)
⇒ page 334 .
Separating centre and rear silencers (engine codes BLG, BMY)
⇒ page 335 .
AG. Volkswagen AG d
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Separating centre and rear silencersV(engine
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1.1 Assemblyssoverview
au - catalytic converter and attachments
or
ac (engine codes
BLG, BMY)
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330 Rep. gr.26 - Exhaust system

1 - Heat shield
2 - 10 Nm
3 - Lambda probe after catalyt‐
ic converter - G130-
❑ Grease only the threads
with “G 052 112 A3”;
“G 052 112 A3” cannot
get into the slots on the
probe body.
❑ If seal is leaking, nip
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5 - Exhaust pipe ss c
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6 - Double clamp, 25 Nm
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❑ For separate replace‐
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satelettronica
silencers
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❑ Tighten bolted connec‐
hole
spec
tions evenly.
es, in part or in w
t to the co
7 - 25 Nm
❑ Renew
rrectness of i
8 - Mounting
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9 - 25 Nm
10 - Exhaust pipe
nform
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❑ With flexible connection

m
(de-coupling element).
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❑ Do not bend flexible
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connection more than
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10° - otherwise it can be
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11 - 25 Nm
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12 - 23 Nm
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❑ Renew
❑ Coat studs of turbocharger with high-temperature paste.
13 - Catalytic converter with exhaust pipe
14 - 25 Nm
15 - Bracket
16 - Lambda probe - G39- , 50 Nm
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” cannot get into the slots on the probe body.
❑ Remove and install using ring spanner for Lambda probe - 3337-
17 - 10 Nm
18 - 25 Nm
❑ Renew studs and fastening nuts.
❑ Screw studs into cylinder head until they project by 25 mm
❑ Coat studs with high-temperature paste.
❑ Observe tightening sequence and specified torques: items -A- to -I- ⇒ page 237 .
1. Removing and installing parts of exhaust system 331

❑ The turbocharger and the exhaust manifold can only be renewed together.
1.2 Assembly overview - catalytic converter and attachments (engine code

BWK)
1 - Seal
❑ Renew
2 - 25 Nm
❑ Renew
3 - Exhaust pipe
4 - Double clamp, 25 Nm
❑ For separate replace‐
ment of centre and rear
silencers
❑ Tighten bolted connec‐
satelettronica
tions evenly.
5 - 10 Nm
6 - 25 Nm
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10 - 25 Nm
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11 - Bracket
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12 - Lambda probe after cat‐

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alytic converter - G130-

h re
ole,
spec
❑ Grease only the threads

t to the co
with “G 052 112 A3”;

“G 052 112 A3” cannot
get into the slots on the
rrectne
probe body.
❑ If seal is leaking, nip
ss
open and renew.

o
cial p
f in
13 - 25 Nm
form
mer
atio
14 - Spring
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15 - Bracket
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16 - 25 Nm
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17 - Mounting
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18 - Exhaust pipe t. C rig
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❑ With flexible connection (de-coupling element). op Vo
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❑ Do not bend flexible connection more than 10° - otherwise it can be damaged.
Prote AG.
19 - 25 Nm
❑ Renew
20 - 23 Nm
❑ Renew
❑ Coat studs of turbocharger with high-temperature paste.

21 - Catalytic converter with exhaust pipe

22 - 25 Nm
23 - Bracket
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25 - Lambda probe - G39- , 50 Nm rise
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❑ Remove and install using ring spanner for Lambda probe - 3337-
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26 - 25 Nm
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ab
❑ Renew studs and fastening nuts.
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❑ Screw studs into cylinder head until they project by 25 mm
wit
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❑ Coat studs with high-temperature paste.
hole
spec
❑ Observe tightening sequence and specified torques: items -A- to -I- ⇒ page 237 .
es, in part or in w
t to the co
❑ The turbocharger and the exhaust manifold can only be renewed together.
rrectness of i
28 - Heat shield
l purpos
satelettronica
1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY)
nform
mercia
a
com
tion in
1 - Mounting
r
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thi
s
2 - 25 Nm
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3 - Bracket
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4 - Centre silencer
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❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
❑ Separating centre and
rear silencers ⇒ page
335
5 - 25 Nm
6 - Bracket
sition
7 - Mounting
8 - Rear silencer
9 - Mounting

1.4 Assembly overview - silencer with mountings (engine code BWK)
1 - Exhaust pipe with centre

and rear silencers
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Aligning exhaust sys‐
tem free of stress
2 - 20 Nm agen
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3 - Bracket ed by ara
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6 - Mounting
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7 - 25 Nm
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8 - Bracket
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9 - 25 Nm
es, in part or in w
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10 - Tunnel cross-piece
11 - 25 Nm
rrectness of i
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1.5 Removing and installing front exhaust
agen
Prote AG.
pipe (engine code BWK)

Removing
– Remove right drive shaft ⇒ Repairing drive shafts; Rep. gr.
40 ; Removing and installing drive shafts .

AG. Volkswagen AG d
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– Loosen securing nuts of double clamp -arrows- and slide it s
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es, in part or in w
satelettronica
t to the co
rrectness of i
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nform
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Prote AG.

– Unscrew propshaft securing bolts at bevel box ⇒ Rear prop‐
shaft and final drive; Rep. gr. 39 ; Removing and installing
propshaft .
– Push propshaft aside.
– Lower subframe ⇒ Subframe, anti-roll bar, suspension links;
Rep. gr. 40 ; Lowering subframe .
– Remove exhaust pipe forwards.
Installing
Installation is performed in the reverse order of removal.
Specified torques:
Pendulum support ⇒ page 27
Exhaust pipe ⇒ page 332
1.6 Separating centre and rear silencers

(engine codes BLG, BMY)

♦ The connecting pipe can be cut through at the cutting location

in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
♦ Chain-type pipe cutter - VAS 6254-
Or
satelettronica
♦ Pneumatic sabre saw - V.A.G 1523A-
Procedure
olkswagen AG
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– Cut through exhaust pipe at cutting olks point -arrow 2- using s not g
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chain-type pipe cutter - VAS ed
6254-
byV or pneumatic sabre saw - uara
V.A.G 1523A- . horis nte
e t or
au ac
– Position double clamp ss -4- centrally between side marks when
installing, arrows -1- and -3-.
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spec
t to the co
– Install double clamp so that bolt ends do not protrude beyond

lower edge of double clamp -arrow-.
rrectne
• Threaded connection faces to rear.

ss o
– Align rear silencer free of stress ⇒ page 337 .

cial p
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Specified torques
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Component Nm
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Double clamp 25
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Rep. gr.26 - Exhaust system
Align rear silencer.

– Align rear silencer so that dimensions -a- are identical.
1.7 Separating centre and rear silencers

(engine codes BWK)
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centren Aand
G. Vorear
lkswasilencers
gen AG separately.
age does
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♦ The cutting pointbis y V marked by an indentation on the
ol ot g outside
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of the exhaust
ir sepipe.
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Special tools
ss
aand
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workshop equipment required ra
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♦ Chain-type pipe cutter - VAS 6254-

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spec
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Or
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♦ Pneumatic sabre saw - V.A.G 1523A-

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– Cut through exhaust pipe at separating point -2- using chain-

type pipe cutter - VAS 6254- or pneumatic sabre saw - V.A.G
1523A- .
– Position double clamp centrally at side marks -1- and -3- when
installing.
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– Install double clamp so that bolt ends do not protrude
Vol
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a
not
lower edge of double clamp -arrow-. ed by gu
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• Threaded connection faces to rear. ho eo
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– Align rear silencer free of stress ⇒ page 338 .
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Specified torques
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Component Nm
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Double clamp 25
h re
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spec
t to the co
Align rear silencer.
rrectne
– Align rear silencer so that dimensions -a- are identical.
ss o
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mer
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28 – Ignition system
1 Repairing ignition system
General notes on ignition system
♦ The engine control unit - J623- is capable of self-diagnosis.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ In some tests, a fault may be detected and stored by the en‐
gine control unit - J623- . Therefore, after completing all
checks and repairs, read the fault memory and erase if nec‐
essary.
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Assembly overview - ignition
ksw
agesystem ⇒ page 339
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Problem solutionisfor
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ed Hall sender - G40- (engine codes BLG, ran BMY)
⇒ page 340 uthor tee
or
s a ac
Removing sand installing ignition coils with output stage ⇒ page
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341 .
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Safety precautions ⇒ page 343 .
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Spark plug test data ⇒ page 343 .
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1.1 Assembly overview - ignition system
hole
spec
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1. Repairing ignition system 339

1 - Connector
❑ Black, 4-pin.
❑ With assembly tool -
T10118- .
2 - Ignition coil 3 with output
stage - N291-
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N292-
⇒ page 341
3 - Connector
❑ Black, 2-pin.
❑ For knock sensor 1 -
G61- .
❑ Connector contacts are
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gold-plated. wage
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4 - Knock sensor 1 - G61- byV ua
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❑ Connector contacts are utho
or
gold-plated. ss
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❑ To remove, remove su‐

un
pt
percharger ⇒ page 255 .
an
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5 - 20 Nm
pe
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ot
❑ The specified torque in‐
wit
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fluences the function of
h re
hole
the knock sensor.
spec
es, in part or in w
6 - Connector
t to the co
❑ Black, 3-pin.
❑ For Hall sender - G40- .
rrectness of i
❑ Problem solution if connector has slipped ⇒ page 340
l purpos
7 - Hall sender - G40-

❑ Problem solution if connector has slipped ⇒ page 340
nform
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8 - O-ring
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9 - 10 Nm
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10 - Spark plug, 25 Nm
um
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❑ Remove and install with spark plug socket and extension - 3122 B-
n
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❑ Type and electrode gap ⇒ page 343 .
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11 - Wiring guide
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❑ Bolt to camshaft housing with 5 Nm torque.
AG.
12 - Earth wire
❑ Loosen or tighten only with ignition switched off.
13 - 10 Nm
❑ Loosen or tighten only with ignition switched off.
1.2 Problem solution for Hall sender - G40-
340 Rep. gr.28 - Ignition system

Engine numbers affected

Engine code BLG: engine number 002 900 ► - Engines ► model
year 2007
Engine code BMY: engine number 001 600 ► - Engines ► model
year 2007
Note
Engines as of model year 2007 ► are not affected.
Problem
Slipped connector on Hall sender - G40-
Procedure
– In case of complaint, place connector -1- back on Hall sender
- G40- so that it can be heard to engage.
– Secure connector -1- additionally with cable tie -2- 4-5 mm
wide.
satelettronica
– Guide pointed end from Hall sender - G40- through connector
-1- and the release clip.
– Bend end of cable tie -2- down and place round Hall sender -
G40- .
– Fix cable tie -2- on the edge next to the wires and pull tightly.
Wire may not be trapped by the cable tie -2-.
– Cut off remainingwend
agen of the cable tie
AG. Volkswagen AG-2-.
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1.3 ss
au Removing and installing ignition coils ra
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with output stage
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spec
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rrectness of i
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Tiguan 2008 ➤ , Touran 2003 ➤gen AG. Volkswagen AG d
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4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, lksw
osupercharger) - Edition 08.2017
not
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♦ Puller - T10094 A- tho
or
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The ignition coil housings with output stages have been modified.
m
atio
m
As a result, these ignition coils can only be removed and installed

o
n in
c
with puller - T10094 A- . The previous puller - T10094- can con‐

or
thi
tinue to be used if modified as described below.
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– Remove marked area -2- using suitable workshop equipment
f
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t.
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to attain the new nominal dimension -B- of 18 mm.
Co
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– Add the letter A to the end of tool designation -1-.
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Removing cted agen
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– Unscrew securing bolts -1- from crankcase breather union and

non-return valve.
– Pull off connector -2- from turbocharger air recirculation valve
- N249- and pull off hose connection -3-.
– Carefully pull hose -4- off intake manifold connection.
– Fit puller - T10094 A- on ignition coil with final output stage

-arrow-
– Slightly pull out ignition coil with output stage.
– Fit assembly tool - T10118- as shown.
– Carefully release connector locking mechanism and pull off
connector.
Installing
– Fit puller - T10094 A- on ignition coil with final output stage.
– Push connector onto ignition coil with output stage until it en‐
gages audibly.

– Press ignition coil with final output stage into cylinder head in
AG. Volkswagen AG d
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1.4 Safety precautions
spec
t to the co
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
rrectne
running or being turned at starter speed.
s
♦ Switch off ignition before connecting or disconnecting injection
s o
satelettronica
and ignition system wiring as well as test instrument cables.
cial p
f inform
Note the following if testers and measuring instruments have to
mer
atio
be used during a road test:
om
n
c
i
♦ Test and measuring instruments must always be secured to
or
n thi
e
rear seat and operated by a second person from this location.

t
sd
iva
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pr
c
If test and measuring instruments are operated from front pas‐
um
r
fo
en
ng
senger seat and the vehicle is involved in an accident, there is a

t.
yi Co
possibility that the person sitting in this seat may receive serious Cop py
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injuries when the airbag is triggered. opyri
gh by
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♦ If the engine is to be turned at starter speed without starting:
lksw
cted agen
Prote AG.
– Pull all 4-pin connectors -arrows- off ignition coils with final
output stage. ⇒ page 341
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er; fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
1.5 Test data, spark plugs

Firing order 1-3-4-2
Spark plugs
VW part number *) 13)
101 905 622
Electrode gap 0.8 to 0.9 mm
Specified torque 25 Nm
Change interval for Golf and Golf Plus ⇒ Maintenance ; Booklet 38 “Additional work
based on time and/or distance”
Change interval for Touran ⇒ Maintenance ; Booklet 18.1 “Additional work


Change interval for Tiguan ⇒ Maintenance ; Booklet 24.1 “Additional work
13) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
satelettronica
AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
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mer
atio
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Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2017 Volkswagen AG, Wolfsburg K0058993820

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Assembly overview - parts l and ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.5 Removing and installing poly V-belt (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.6 Removing and installing control housing (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.7 Removing and installing valve timing housing (Tiguan, Touran) . . . . . . . . . . . . . . . . . . . . 44

1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 50

2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1.3 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.6 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.11 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

1.12 Removing and installing coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1.13 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.3 Removing and installing compressor (engine code BWK) . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

3.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

3.2 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

3.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

3.5 Removing and installing charge air cooler, Tiguan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.1 Assembly overview - parts l and II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1.2 Assembly overview - part I, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

1.3 Assembly overview - part II, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

1.4 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

1.5 Checking vacuum reservoir for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1.6 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

1.9 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 nform

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

1.2 Problem solution for Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

1.4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

00 – Technical data AG. Volkswagen AG d

1.1 Engine number

Engine code and engine number can be found on the sticker

♦ Vehicles for certain export countries have no type plate. Fitting

1.2 Engine data

RON min. 95 unleaded 95 unleaded 95 unleaded

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

♦ Check these holes before dismantling/assembling and install

Converting engine support - T40075-

– Scribe dimensions -a- and -b- as shown.

Dimension -a- = 24.5 mm

Dimension -b-: 49.0 mm

– Mark position with a centre punch.

1. Removing and installing engine (Golf, Golf Plus, Touran) 3

Special tools and workshop

♦ Engine support - T40075- with adapters /4, /5, /6 or engine