Service Workshop Manual Eos 2006 > , Golf 2004 > , Golf 2009 > , Golf Plus 2005 > , Golf Plus 2009 > , Passat 2006 > , Passat 2011 > , Passat Variant 2011 > , Scirocco 2009 > _ Tiguan:2008 > Edition 07.2015 9 Service Department. Technical InformationService List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system 21 - Turbocharging/supércharging 24 - Mixture préparation - injection 26 - Exhaiist system 28 - Ighition system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Volkswagen AG, Wolfsburg 0059101820Eos 2006 > , Golf 2004 > , Golf 2009 > , 4-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 Contents 00 --Technical data 1 1 Technical data > 1 1.4 Engine number i, 1 12 Engine deta 4 1 10 - Removing and installing engine .... 3 4. Removing and instaling engine (Golf, Golf Plus, Eos, Scirocco) 3 14 Removing engine i 3 12 Securing engine to assembly stand 3 14 13 Installing engine : " 14 Specified torques 4 1.5 Assembly mountings 4 116 Additional information and assembly work for vehicles vith air conditioner 15 2 Removing and installing engine (Tiguan) j 16 24 Removing engine . 16 22 Securing engine to assembly stand . 24 23 Installing engine 25 24 — Specified torques. a 25 Assembly mountings ....... ee Glin eeeevereeees vecccceeees 2B 26 Additional information ang assembly work for Vehicles with air conditioner ce 28 3” “Removing and range Pasgeo 30 3.4. Remying engine .. At... 30 32 — Securing’engine to assembly Sand “4 3.3 Installing engine . “1 3.4 Specified torques. 44 3.8 Assembly mountings bev 44 3.6 Additional information and assembly work for vehicles with air conditioner ce 48 413~- Crankshaft group .... bob ec bees eeees sete tetesseteeeesesneeeess 46 1 Dismanting and assembling engine 46 1.1 Assembly overview - parts | and I 46 12 Assembly overview- part |, belt drive .. 48 1.3. Assembly overview - part Il, cylinder block 49 1.4 Removing and installing poly V-belt. cee 4.8 Removing and instaling valve timing housing (Golf, Golf Plus, Eos, Scirocco) 52 4.6 Removing and installing valve timing housing (Tiguan) 57 1.7. Removing and installing valve timing housing (Passat) 61 1.8 Removing and installing ancillary bracket 66 2 Removing and installing sealing flanges and flywheel or drive plate 68 24 Assembly overview 68 22 — Removing and installing engine speed sender G28 69 23 Renewing crankshaft oil seal - belt pulley end 70 24 Removing and installing crankshaft pulley . 72 2.5 — Renewing crankshaft sealing flange - flywheel end 75 3 Crankshaft a4 3.1. Assembly overview a4 32 Pulling needle bearing out of and driving into crankshaft 85 3.3. Crankshaft dimensions 86 4 Dismantling and assembling pistons and conrods 87 4.1 Assembly overview 87 42 Checking piston 89 4.3 Separating new conrod 80 contanis i15 17 19 20 Eos 2006 > , Golf 2004 > , Golf 2009 »..Golf Plus 2005 > , Golf Plus . 4-cylinder injection engine 1:4 | direct injectiot engine, turbocharger) - Edition 07.2015 44 Piston and.oyfinder cimensions 45 Removing and installing pistons 4.6 RemoVing and installing oll spray jets... Cylinder head, valve gear .......... : 1 Oylinder head 1.1 “Assembly overview 4.2. © Checking valve timing 1.3 © Adjusting valve timing : 1.42 Checking timing chain... . 3 1.55 Removing and installing timing chain and chain drive for oll pump 1.6. Removing and installing camshaft housing 1.7 Removing and installing cylinder head. 1.8 Checking compression . . 2 Repairing valve gear 24 Assembly overview 22 “Checking camshaft axial clearance 2.3 Removing and installing camshaft . 24 — Reworking valve seats 25 Chedking valve guides 2.6 Renewing valve stem seals Lubrication ler VE WP cece eee eee e eee 1 Removing and installing parts of lubriéatlon systeftt oo. eee : 1.1 Engine oil, oil capacities, enigine oil spetification . 1.2. Assembly overview (* model year 2008) 1.3. Assembly overview (model year 2009») 1.4 Removing and installing oil sump 15. Removing and installing oll pump 1.6 Checking oil pressure and oil pressure switch = COMING eee e cece eee cee ee ee ees ee esse ee eeteseveseeeeneneneeee 1. Removing and installing perts of cooling system 1.1 Assembly overview - parts of cooling system, body side 1.2 Assembly overview - parts of cooling system, engine side 1.3 Coolant hose schematic diagram 1.4 Draining and filing coolant 45 Removing and instaling radiator fan V7 and racator fan 2 V177 (Gof, Golf Pus, Eos, Scirocco)... . . 4.8 Removing and installing radiator fan V7 and radiator fan 2.V177 Cowan. Passat) 1.7 Checking cooling system for leaks . cee 1.8 Removing and installing radiator (Goff, Golf Plus, Scirocco, Eos) 1.9 Removing and installing radiator (Tiguan, Passat) 1.10 Removing and installing auxiliary radiator for charge air system (Tiguan, Passat) 1.11. Removing and installing coolant pump 1.12 Removing and installing coolant circulation pump V50 Fuel supply system 1 Safety precautions . . 44 ‘Safety precautions when working on 1 fuel supply system . 1.2. Releasing pressure in high-pressure area wee 2 ‘Separating push-on couplings 3 Fuel tank (Golf, Golf Plus, Scirocco) . . 3.4 Assembly overview - fuel tank 3.2. Emptying fuel tank 3.2. Removing and installing fuel tank 90 1 92 93 93 93 96 99 107 113 121 127 130 133 - 133 135 135 - 136 137 138 140 140 140 140 143 - 145 147 149 152 152 153 155 156 157 . 160 . 164 . 162 163 165 167 71 173 -176 .. 176 . 176 .17 . 178 181 - 181 182 185 Contents21 4-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 4 Fuel tank (Passat) 187 44 Assembly overview - fuel tank 187 42 Emptying fuel tank 188 43. Removing and installing fuel tank... oy 191 5 Fuel tank (Eos) eres «Pe, 195 5.1 Assembly overview -fueltank 195 5.2 Emptying fuel tank ey ve 197 5.3 Removing and instaling uel tenk 199 6 Fuel tank (Tiguan) 202 8.1 Assembly everview- fuel tank (Tiguan) 202 62 Draining fuel tank (Tiguan) 204 8.3 Removing and installing fuel tank (Tiguen) ce chev 206 7 Repairing fuel supply system (Golf, Golf Pus, Scirocco, Eos) ait 7.4 Rules for cleanliness ait 72 Crash fuel'shut-off ait 73 stalling fuel delivery unit (Golf Plus, Golf, Scirocco, Eos) ............ 212 74 stalling fuel gauge sender G ay... ci 214 7.8 Checking fuel pump .... = cece anes eed seeet Bee. 215 8 Repairing fuel supply re) 227 8.4 Rules for cleanliness. fees. 27 82 Crash fuel shut-off wefiecees 227 8.3 Removing and installing fuel delivery unit wee eetee eee ee eee, 228 8.4 Removing and installing fuel gauge sender G ..... . v8 231 85 Checking fuel pump... . é 233 9 Repairing fuel suppiy(Tiguan) a. 242 9.4 Rules for cleanliness <2, ....... 5 soos 242 92 — Crash fuel shutoff 242 93 Removing and installing fuel delivery unit (Tiguan) 7 243 9.4 — Removing and installing fuel gauge serider G (Tiguan) 245 8.5 Removing and installing suction-jet pump (Tiguan) 246 96 Removing and installing fuel gauge sender 2 G169 (Tiguan) 249 8.7 Removing and installing fuel pump control unit J538 (Tiguan) 248 98 — Checking fuel pump (Tiguan) 251 10 Repairing electronic power control (EPC) 260 10.1. Assembly overview 260 10.2 Removing and installing accelerator module ..... cecceeeeeeeeeeeees 280 11 Activated charcoal iter system (Gott, Got Pus, Eos, Scirocco) weve ee eee, 262 41.4 Assembly overview (Golf, Golf Plus, Eos, Scirocco) 6... sees eeeceeeeeeeeeeees 262 41.2. Checking fuel tank breather (Golf, Golf Plus, Eos, Scirocco) - . 263 11.3. Rules forcleanliness ....... een ceeeeeeeeees 288 12 Activated charoa tt systm (Passat) «o-oo see sso eeeeece serene 288 12.1 Assembly overview : vette : +. 265 122 Checking fuel tank breather ......... : cic eee neennes 286 123° Rules forcleanliness ....... vette eettteee nee ceceeeeeeees 287 13 Activated charcoal fiter system (TiQUan) 0... eee eee eevsveeeeeeeeeeeeeeee sees 268 13.1. Assembly overview (Tiguan) 268 13.2 Checking fuel tank breather (Tiguan) 269 13.3. Rules for cleanliness 270 Turbocharging/supercharging 6.66... see c eens e eee e eee e tenn e eee 271 1 Turbocharger ...... ceeeeeeeeeeeeeet et tettttttttttttteeeeeeees OT 4.1 Assembly everview- turbocharger.» ceeeteeetneees i : 274 12 Part Fe ttt aeee ees 28 13° Parti cette tetas vieteeeenees sees 274 consents Hii4-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 1.4 Removing and installing turbocharger 1.5 Removing and installing compressor housing and turbine housing 4.6 Checking vacuum unit for turbocharger 4.7 Removing and installing vacuum unit for turbocharger 1.8 Adjusting vacuum unit for turbocharger 2 Charge air system 2.1 Assembly overview charge air system 22 Removing and installing intake manifold charge air cooler. 24 - Mixture preparation - injection .. . 1 Injection system 4.1 Assembly overview parts | and Il, intake manifold 1.2 Assembly overview - part |, intake manifold 1.3. Assembly overview - part I, intake manifold 14 Assembly overview - fuel rail wth injectors 1.5 Assembly overview - air fiter 4.6 Removing and installing air fiter 4.7 Removing and installing throttle valve module J338 1.8 Cleaning throttle valve module J338 19 Removing and installing intake manifold 10 Assembly overview - high-pressure\pilmp 11 Checking fuel pressure sender 6247 42 Removing and installing high-pressure pump 13 Removing and installing injectors 14 Renewing Teflon seat and support washer on injector 18 Safety precautions 16 Rules for cleanliness 17 Technical data 2 Engine control unit J623 . 24 Removing and:installing engine control unit 4623 (Golf . 2008, Eos) 2.2 Removing and installing anti-theft engine control unit J623 ot 2008, Eos > 10. 2008) 23 Removing and installing engine control unit J623 (Golf 2009»). 2.4 — Removing and installing anti-theft engine control unit J623 (Gof 2009 », Scirocco 10.2008, Pessat 2011) 2.5 — Removing and installing engine control unit J623 (Golf Plus) 2.6 Removing and installing anti-theft engine control unit J623 (Golf Plus) 2.7 — Removing and installing engine control unit J623 (Passat 2006 ~) 2.8 Removing and installing antitheft-secured engine control unit J623 (Passat 2006 *) 2.9 Removing and installing engine control unit J623 (Scirocco) 2.10 Removing and installing anti-theft engine control unit J623 (Scirocco * 09.2008) 2.11. Removing and installing engine control unit J623 (Tiguan) 2.12 Removing and installing anti-theft engine control unit ane - iS 11.2008 >, © 26 - Exhaust system oo... 6. ee Gs, 1 Removing and installing parts of exhalisteystem oJ 1.4. Assembly overview - catalytic converter and attachments 1.2 Assembly overview - silencer with mountings (Golf, Golf Plus, Scirocco) 1.3 Assembly overview - silencer with mountings (Passat 2006 ») 1.4 Assembly overview - silencer with mountings (Passat 2011 ) 1.5 Assembly overview - silencer with mountings (Eos) 1.6 Assembly overview - silencer with mountings (Tiguan) 4.7 Removing and installing centre and rear silencers (Golf, Golf Plus, Scirocco, Eos) 1.8 Detaching centre and rear silencers (Passat) 1.9 Separating centre and rear silencers (Tiguan) 1.10 Installation position and specified torque of clamp 275 280 » 284 286 288 - 295 295 296 298 298 298 300 301 302 302 303 304 307 308 309 310 313 37 320 323 325 325 326 326 327 330 331 333, 335 337 338 339 341 342 343 346 348 348 349 360 351 362 353 353 . 355 387 368 IV contantsEos 2006 > , Golf 2004 > . Golf 2009 > , Golf Plus 2005 ~ . Golf Plus 4-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 28 - Ignition system veveeeeeeeees fete eteeetreee esses 360 1 Repairing ignition system 360 1.1 Assembly overview - ignition system 360 1.2. Removing and installing ignition coils with output stage 261 13 Safety precautions 362 14 Test data, spark plugs 363 Contents VEos 2006 > , Golf 2004 > , Golf 2009 > , Golf Plus 2005 > , Golf Plus . 4-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 Vi_ contonsEos 2006 > , Golf 2004 > , Golf 2009 ~ , Golf Plus 2005 > . Goif Plus 4-cylinder injection engine (1.411 direct injection engine, turbocharger) - Edition 07.2015 we} Technical data 1 Technical data (VRL008278; Edition 07.2015) Engine number = page 1 Engine data ~ page 1 1A Engine number = Detach hose from activated charcoal fiter at hose clip -arrow- Engine code and engine number can be found on the sticker -errow- on the control housing, ‘The engine code is also on the vehicle data sticker and on the crankcase above the gearbox The engine number consists of up to nine characters (alphanu- meric). The first part (maximum 3 characters) makes up the “engine code", and the second part (6 characters), the ‘serial number. If more than 999,999 engines were produced with the same code letters, the first of the six digits is replaced by a letter. Vehicles with four digit engine codes Starting with the letter “C’, new four digit engine codes have been introduced. The first 3 digits denote the mechanical design of the engine and are stamped on the engine as before. The fourth digit denotes the performance and torque rating of the engine and de- pends on the engine control unit - J623- . The four digit engine ‘code can be found on the identification plate, the vehicle date sticker and on the engine control unit. Note Fitting locations of vehicle data sticker > Maintenance ; Booklet ; Venicle data sticker 1.2 Engine data Engine codes CAXA Manufactured otf 2004+ 07.07 Golf Plus 2005" o7.07+ Passat 2006" 11.07 Eos 2006 (up to to 11.07 10.09 EU4) Emission standards cus 1. Tochrical data 14-cylinder injection engine (1.4 | direct injection engine, turbocharger) - Edition 07.2015 [Engine codes ‘CAXA (Capacity om: 1390 Output KW at rpm] 90/5000 Torque Nm at rpm 200/1500-4000 Bore Diameter, mn] 765 Stroke mm 75.6 ‘Compression ratio 10 RON min. 85 tinjeaded Injection, ignition Motronic MED 17 Firing order 1342 Type of mixture formation Homogeneous: Turbocharging/supercharging ‘Turbocharger [Engine codes CAXA CMSB Manufactured Gait 2009+ 07.08" - 3 Golf Plus 2009" 02.09" - Stirocco 2009+ 11.08" 06.14 Eas 2006+ (from| 11.07 - 11.08 EUS) Tiguen 2008+ 07.10" Passat 2006 11.07 _ Passat2011> 41.40" _ Emission stand- EUS Bus ards Capacity ‘em 1390 1390 Output KW at rom 90/5000 a 90/5000 Torque Nm at rpm 200/150-4000, 200/150-4000 Bore Diameter, mm 765 © 765 [Stroke mm 756 75.6 |Compression ratio 10 10 RON min 95 unleaded 95 unleaded Injection, ignition Motronic MED 17 Motronic MED 17 Firing order 1342 1342 Type of mixture formation Homogeneous Homogeneous Turbocharging/supercharging ‘Turbocharger Turbocharger 2 Rep. 07: 00- Technical data