Engine Dnpa DNFC Dnfe DNFG Dnna Dsfe Drna DNND DSFB DSFF Repair Manual Eng

Service
Workshop Manual
Arteon 2021 ➤,
Arteon Shooting Brake 2021 ➤,
Golf 2020 ➤, Golf Variant 2021 ➤,
Passat 2019 ➤, Passat Variant 2019 ➤,
Polo 2018 ➤, T-Roc 2018 ➤,
Tiguan 2021 ➤
4-cylinder direct-injection engine (2.0l, 4V, TFSI,
EA888evo4)
Engine ID
DNP DNF DNF DNF DNN DSF DRN DNN DSF
A C E G A E A D B
DSFF
Edition 07.2021
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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.
Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2020 ➤, Golf Variant 2021 ➤, ...
4-cylinder direct-injection engine (2.0l, 4V, TFSI, EA888evo4) - Edition 07.2021
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Initial diagnoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.6 Checking adjustment of assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.7 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Contents i
3.4 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.7 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.8 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.3 Renewing seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.2 Assembly overview - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.4 Removing and installing bearing saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.5 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.6 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.1 Assembly overview – valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.3 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 233
4.4 Removing and installing camshaft control valves N205/N318 . . . . . . . . . . . . . . . . . . . . . . 234
4.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 259
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
ii Contents
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3.3 Removing and installing crankcase pressure sensor G1068 . . . . . . . . . . . . . . . . . . . . . . . . 265
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.2 Assembly overview - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . 267
4.3 Removing and installing oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.4 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 271
4.5 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 272
4.6 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2.3 Assembly overview – coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.4 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
2.7 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.8 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 301
2.9 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 304
2.10 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . . . 305
2.11 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.2 Assembly overview – radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
4.3 Assembly overview - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.5 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.6 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4.7 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1.1 Assembly overview – turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1.3 Removing and installing charge pressure control module GX34 . . . . . . . . . . . . . . . . . . . . 353
1.4 Removing and installing sender 1 for turbocharger speed G688, DNFC, DNFE, DNFG,
DSFB, DSFE, DSFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
2.1 Assembly overview – charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
2.5 Removing and installing turbocharger air recirculation valve N249, DNFC, DNFE, DNFG,
DSFB, DSFE, DSFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Contents iii
2.6 Removing and installing air intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

2.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
2.1 Connection diagram – vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
3.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4.1 Assembly overview – air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.3 Removing and installing air guide on lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.1 Assembly overview – intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
5.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
5.5 Removing and installing intake manifold flap valve N316 . . . . . . . . . . . . . . . . . . . . . . . . . . 412
5.6 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
6.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
6.2 Control unit for structure-borne sound J869 and actuator for structure-borne sound R214 . . 418
6.3 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
6.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
6.5 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
6.6 Removing and installing pressure differential sender for particulate filter G1037 . . . . . . . . 423
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
8.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
9.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
1.1 Assembly overview – silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
1.2 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
1.6 Removing and installing bracket for catalytic converter, Tiguan . . . . . . . . . . . . . . . . . . . . 464
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
2.2 Assembly overview - bracket and pipes for pressure differential sender for particulate filter
G1037 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
iv Contents
2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

2.4 Removing and installing holder of pressure differential sender for particulate filter G1037 . . 484
2.5 Removing and installing exhaust flap control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
3.1 Assembly overview – exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 486
3.2 Removing and installing parts of exhaust gas temperature regulation . . . . . . . . . . . . . . . . 487
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
1.2 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Contents v
vi Contents
00 – Technical data
1 Safety information
(VRL015876; Edition 07.2021)
⇒ r1.1 egulations for working on fuel supply”, page 1
⇒ m1.2 easures when working on vehicles with start/stop sys‐
tem”, page 1
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on ignition system”, page 2
⇒ p1.5 recautions when working on the cooling system”, page
2
⇒ p1.6 recautions when working on exhaust system”, page 3
1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear safety goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connec‐
tion and carefully loosen the connection.
Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the
door contact switch activates the fuel pump. Escaping fuel can
ignite and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety measures when working on vehicles with start/stop system

Risk of injury from engine starting unexpectedly
If the vehicle’s start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if testing and measuring instruments are not se‐
cured
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring
equipment on the rear seat.
1.4 Safety precautions when working on ignition system

Risk of injury due to electric shock
The ignition system is under high voltage when the engine is
running. Touching the ignition system may result in an electric
shock.
– Do not touch or disconnect ignition cables when the engine
is running or being turned at starter speed.
Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐
gine while it is running may damage components.
– Switch off the ignition before connecting or disconnecting
electric cables.
– Switch off the ignition before washing the engine.
1.5 Safety precautions when working on the cooling system

Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure.
Hot steam/hot coolant can escape - risk of scalding.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on exhaust system

Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.
– Never open an exhaust gas temperature sender by cutting,
sawing or any other means.
Risk of injury due to hot condensate and particles in the ex‐
haust system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.
Risk of damage to flexible joint

Do not allow the flexible joint to bend by more than 10°.
Install flexible joint so that it is not under tension.
Take care not to damage metal braiding on decoupling element.
1. Safety information 3
2 Identification
⇒ n2.1 umber/engine data”, page 4
2.1 Engine number/engine data

Engine number
The engine number (“code letters” and “serial number”) can be
found at the joint between the engine and gearbox.
The engine code is also stamped on the cylinder block behind

the oil filter.
In addition, there is a sticker on the right of the timing chain
cover with “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine
and are stamped on the engine. The fourth digit shows the
engine output and torque and varies according to engine control
unit. The four-digit engine code can be found on the identifica‐
tion plate. It can also be read from the engine control unit.
Engine data
Codes DNFG DSFB DSFE DSFF DNFC DNFE
Manufac‐ Golf 08.2020 ► --- 02.2021 ► 08.2021 ► 08.2020 ► ---
tured from Tiguan 08.2020 ► --- 02.2021 ► --- --- ---
Arteon 11.2020 ► 09.2021 ► --- --- --- 11.2020 ►
T-Roc --- --- --- --- 11.2020 ► ---
Passat --- --- --- --- --- 11.2020 ►
Power class LK3 LK3 LK3 LK3 LK3 LK3
Exhaust emission standard EU 6 EU 6 / EU 6 / EU 6 / EU 6 EU 6
LEV3 / LEV3 / LEV3 /
Tier3 Tier3 Tier3
Displace‐ l 2.0 2.0 2.0 2.0 2.0 2.0
ment
Power kW at rpm 235 at 5200 224 at 5350 235 at 5600 235 at 5900 221 at 5300 206 at 4950
to 6600 to 6500 to 6500 to 6500 to 6600 to 6600
Torque Nm at rpm 420 at 2000 400 at 2000 400 at 2000 380 at 1900 400 at 2000 400 at 2000
to 5550 to 5350 to 5600 to 5900 to 5300 to 4950
Bore Diameter, mm 82.5 82.5 82.5 82.5 82.5 82.5
4 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

Codes DNFG DSFB DSFE DSFF DNFC DNFE

Stroke mm 92.8 92.8 92.8 92.8 92.8 92.8
Compression ratio 9.3:1 9.3:1 9.3:1 9.3:1 9.3:1 9.3:1
RON 98 98 98 98 98 98
Injection system Direct injec‐ Direct injec‐ Direct injec‐ Direct injec‐ Direct injec‐ Direct injec‐
tion tion tion tion tion tion
Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
der
Charging Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐ Turbo‐
charger charger charger charger charger charger
Camshaft timing adjust‐ yes yes yes yes yes yes
ment
Variable Exhaust Exhaust Exhaust Exhaust Exhaust Exhaust
valve tim‐ side side side side side side
ing
Secondary air injection no no no no no no
Valves per cylinder 4 4 4 4 4 4
Oil pressure control yes yes yes yes yes yes
Particulate filter yes yes yes yes yes yes
Codes DNPA DRNA DNNA DNND

Manufactured Golf 08.2020 ► 07.2021 ► --- ---
from Tiguan 08.2020 ► --- 08.2020 ► ---
Arteon --- --- 11.2020 ► ---
Passat --- --- 11.2020 ► ---
Polo --- --- --- 04.2021 ►
Power class LK2 LK2 LK1 LK1
Exhaust emission standard EU 6 LEV3 / Tier3 EU 6 EU 6
Displacement l 2.0 2.0 2.0 2.0
Power kW at rpm 180 at 5000 to 180 at 5000 to 140 at 4200 to 152 at 4600 to
6500 6500 6000 6000
Torque Nm at rpm 370 at 1600 to 370 at 1600 to 320 at 1500 to 320 at 1500 to
4300 4300 4100 4500
Bore Diameter, mm 82.5 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8 92.8
Compression ratio 9.6:1 9.6:1 12.2:1 12.2:1
RON 95 95 95 95
Injection system Direct injection Direct injection Direct injection Direct injection
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Charging Turbocharger Turbocharger Turbocharger Turbocharger
Camshaft timing adjustment yes yes yes yes
Variable valve Exhaust side Exhaust side Inlet side Inlet side
timing
Secondary air injection no no no no
Valves per cylinder 4 4 4 4
Oil pressure control yes yes yes yes
Particulate filter yes yes yes yes
Volkswagen Technical Site: https://vwts.ru
2. Identification 5
3 Repair instructions
⇒ f3.1 or cleanliness”, page 6
⇒ d3.2 iagnoses”, page 6
⇒ o3.3 bjects in engine”, page 7
⇒ c3.4 orrosion”, page 7
⇒ a3.5 nd attachment of lines”, page 7
⇒ r3.6 adiator and condensers”, page 7
⇒ v3.7 acuum system”, page 7
3.1 Rules for cleanliness

Even small amounts of contamination/soiling can lead to de‐
fects. You must therefore comply with the following rules for
cleanliness when working on the fuel supply system, injection
system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly
before opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set -VAS 6122-.
♦ Place removed parts on a clean surface. Cover with lint-free
cloths only.
♦ If repair work cannot be performed immediately, carefully
cover or seal opened components.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts
that have been stored outside their packaging (e.g. in tool
boxes).
♦ When the system is open, do not work with compressed air
or move the vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and wa‐
ter, and reconnect them only when dry.
3.2 Initial diagnoses

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Adapting learnt values after component replacement
The learnt values must be adapted after the following:
♦ Engine renewed.
♦ Sender wheel for engine speed sender -G28- renewed.
♦ Components of chain drive removed and installed or re‐
newed.
♦ Cylinder head removed and installed or renewed.
♦ Camshafts removed and installed or renewed.
♦ Turbocharger or charge pressure control module -GX34- re‐
newed.
♦ Particulate filter renewed.

– Connect vehicle diagnostic tester.

– Switch on ignition and select Guided Functions ⇒ Vehicle
diagnostic tester:
♦ 0001 - Engine electronics
♦ 0001 - Engine electronics, functions
♦ 0001 - Work steps after component replacement
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
3.3 Foreign objects in engine

♦ To prevent the ingress of foreign bodies during work on
the engine, seal open channels of the intake and exhaust
sections with suitable bungs, for example from the engine
bung set -VAS 6122-.
3.4 Contact corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating
are used.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue (ETKA).
3.5 Routing and attachment of lines

♦ To prevent interchanging and to maintain the original instal‐
lation position, mark fuel lines, vacuum lines, pipes/hoses
for activated charcoal filter system and electrical wiring etc.
before removal. Make sketches or take photographs if nec‐
essary.
♦ To avoid damage to lines, ensure adequate clearance from
all moving or hot components in the engine compartment on
account of the confined space.
3.6 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does
not mean that these components have been damaged. It is
not permissible to renew radiators, condensers or charge air
coolers only because of such minor dents.
3.7 Checking vacuum system

3. Repair instructions 7
♦ Hand operated vacuum pump -VAS 6213-
Procedure
– Check all vacuum lines throughout entire vacuum system
for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid
valve to relevant component.
– If a fault has been entered in the event memory, make sure
to check not only all vacuum lines leading to the specified
component, but also those leading to other components.
– If pressure cannot be built-up using hand vacuum pump
-VAS 6213- or pressure immediately drops again, check
hand vacuum pump and connecting hoses for leaks.

10 – Removing and installing engine

1 Removing and installing engine
⇒ e1.1 ngine”, page 9
⇒ e1.2 ngine and gearbox”, page 29
⇒ e1.3 ngine on engine and gearbox support”, page 34
⇒ e1.4 ngine”, page 36
1.1 Removing engine

♦ Engine and gearbox jack -VAS 6931-
♦ Engine support -T10359 A-
♦ Pin -T10359/2-
♦ Adapter -T10359/3-
♦ Securing element from gearbox support -3282-
1. Removing and installing engine 9

♦ Release lever -80 - 200-
♦ Safety goggles
♦ Protective gloves
♦ Stepladder
Note
The engine is removed downwards with gearbox. To do this, the

subframe needs to be removed.
Procedure
CAUTION
The cooling system could be under pressure. Hot steam/hot
coolant can escape - risk of scalding.
Skin and other parts of the body may be scalded.
– Reduce excess pressure by covering cap of coolant ex‐
pansion tank with a suitable cloth and opening it carefully.
– Open filler cap -arrow- for coolant expansion tank.

– Remove subframe without steering rack ⇒ Running gear,
axles, steering; Rep. gr. 40; Subframe; Removing and instal‐
ling subframe without steering rack.
– Remove front parts of left and right front wheel housing lin‐
ers ⇒ General body repairs, exterior; Rep. gr. 66; Wheel
housing liner; Assembly overview - front wheel housing liner.
– Disconnect electrical connector -1-.
10 Rep. gr.10 - Removing and installing engine

– Place drip tray for workshop hoist -VAS 6208- underneath.

– Lift retaining clip -3-, disconnect coolant hose (bottom right)
from radiator and drain off coolant.
– Remove engine cover panel ⇒ page 76 .
– Remove air filter housing ⇒ page 399 .
– Remove air duct on lock carrier ⇒ a4.3 nd installing air guide
on lock carrier”, page 401 .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and reconnecting battery.
– Battery in engine compartment: Remove battery tray -1-

⇒ Electrical system; Rep. gr. 27; Battery; Removing and
installing battery tray.
– Battery in luggage compartment: remove mounting for air
filter housing.
– Separate vacuum hose -2-.
– Press release tabs on vacuum hose -1-, and remove hose

from vacuum pump.

Vehicles without auxiliary heater:
– Lift retaining clips -arrows- and disconnect coolant hoses

from heat exchanger for heater.
– Hold coolant hoses downwards to allow coolant to drain.
Vehicles with auxiliary heater:
– Release hose clip -1-, lift retaining clips -arrows-, and dis‐
connect coolant hoses.
Continued for all vehicles:
– Detach electrical connectors -1, 2- from bracket, unplug con‐

nectors and move electrical wiring clear.
– Loosen clamp -1- for catalytic converter -2-, and push clamp
onto turbocharger.

CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
– Disconnect hose couplings -1- and -2- ⇒ Rep. gr. 20; Plug-in
connectors; Disconnecting plug-in connectors. Detach hoses
from coolant expansion tank -3-.
– If fitted, unscrew bolt -arrow-.

– Release hose clips -1, 2-, and remove coolant hoses.
– Lift retaining clip -arrow- and disconnect coolant hose (top

left) from radiator.

Note
For the work steps below, use removal lever -80 - 200- to unclip
the binding clips.
Golf, Passat, Arteon:
– Separate connector -1- on engine control unit -J623- ⇒ page

425 .
– Remove connectors -2, 3- from retainer and disconnect
them.
– Move electrical lines free.
– Release catches -arrows- and detach cover -1- for electron‐
ics box in engine compartment.
– Release catch using a screwdriver -arrow- and detach cover

-1- for electronics box in engine compartment upwards.

– Remove nut -arrow-, detach electrical wiring and move clear.
Sharan:
– Release and pull off connector on engine control unit -J623-

⇒ page 425 .
– Open cable duct latches on longitudinal member -arrows-.
– Release and disconnect connectors -1- and -2-.

– Open locking elements -arrows- of cable guide, and place

engine wiring harness -3- on engine.
– Move electrical lines free.
– Secure cables to engine using a cable tie.
– Release fasteners -1- in -direction of arrow-, and remove
cover -2- for electronics box in engine compartment.
– Remove nut -arrow-, detach electrical wiring and move clear.

Vehicles with manual gearbox:

– Push back cover for battery positive terminal -1-, and unbolt
battery positive cable from starter solenoid switch.
– Unscrew nut -3- and remove earth wire.
Note
Depending on vehicle version, the earth wire is secured to the

starter bolt.
– Disconnect electrical connections at front left of gearbox.
1- For gearbox neutral position sender -G701-

2- For reversing light switch -F4-
– Disconnect gear selector cable and gate selector cable from
gearbox. Then, unbolt cable support bracket, and lay it to
one side together with cables ⇒ Rep. gr. 34; Selector mech‐
anism; Removing and installing selector mechanism.
– Remove bleeder connection -3- from gearbox.

– To remove bleeder connection -3-, pull out retaining clip -1-

onto stop.
Do not pull out securing clip -2-.
– Seal off open lines and connections if necessary with clean
plugs from engine bung set -VAS 6122-.
Vehicles with dual clutch gearbox:

– Push back cover for battery positive terminal -3-, and unbolt
battery positive cable from starter solenoid switch.
– Loosen nut -arrow-, and remove earth wire.
Note
Depending on vehicle version, the earth wire is secured to the

starter bolt.
– Touch earth connection (without gloves) in order to dis‐

charge yourself.
– Do not touch contacts in the gearbox connector with hands.
– Separate connector -2- for mechatronic unit for dual clutch
gearbox -J743-. To do this, turn rotary fastener in anti-clock‐
wise direction.
– Disconnect selector lever cable from gearbox, and pull it out
of cable support bracket ⇒ Rep. gr. 34; Selector mechanism;
Removing and installing selector mechanism.

Continued for all:
– Loosen bolts -arrows- for gearbox mounting approx. 2 turns.

– Loosen bolts -arrows- for engine mounting approx. 2 turns.
– Loosen hose clips -arrows-, and remove charge air hose -A-.
– Separate connector -1- for radiator fan. To do this, push re‐

taining clip in direction of arrow -A-, and press down release
catch.

– Simultaneously press locking tabs -B- on left and right of ra‐

diator cowl. Detach radiator cowl, and remove it downwards
from radiator.
– Release hose clip -1- and -2- and remove right charge air
hose.
– Seal open lines and connections with clean plugs from en‐
gine bung set -VAS 6122-.
– Cover radiator using protective mat -VAS 531003-.
– Free off coolant hose -3-.

– Unscrew bolts -arrows-.

– Release hose clip -2-.
– Separate electrical connector -1- from charge pressure
sender -G31-.
– Remove air pipe.
Vehicles with auxiliary heater:
– Loosen clamp -1-, unscrew bolt -2-, and remove silencer for
auxiliary heater.
– Before removing the poly V-belt, use a piece of chalk or a

felt pen to mark the running direction.

– To relieve tension on poly V-belt, swivel tensioning device in

clockwise direction -arrow-.
– Remove poly V-belt from poly V-belt pulley of air conditioner
compressor and release tensioning device. Remove locking
pin -T10060 A- if necessary.
CAUTION
Risk of freezing injury caused by refrigerant.
– Do not open refrigerant circuit of air conditioning system.
– Separate connector -1- on air conditioning compressor regu‐

lating valve -N280-.
– Detach air conditioner compressor from bracket (refrigerant
hoses remain connected) and tie up to right side. Do NOT
stretch, kink or bend refrigerant lines and hoses while doing
so.
– Unbolt drive shafts from flange shafts on left and right
⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Removing and installing drive shaft.
– Tie up drive shafts to rear.
Note
Take care not to damage the surface protection of drive shaft.
– If fitted, release electrical connector for auxiliary hydraulic

pump 1 for gearbox oil -V475- -a-, and pull off connector -b-.

Vehicles with front differential lock
– Disconnect electrical connector -arrow- of axle differential

lock control unit -J647-.
Vehicles with all-wheel drive:
– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.
– Mark position of propshaft with flexible coupling relative to
output shaft of bevel box -arrows-.
– Unbolt propshaft from bevel box -arrows- ⇒ Rep. gr. 39;

Propshaft; Removing and installing propshaft.

– If necessary, counterhold at rear final drive when loosening

or tightening propshaft.
– Secure support -T10323- with a bolt on inside rear threaded

hole for subframe.
– A securing bolt from the subframe is suitable for this.

– Lay cloth -A- on support and place propshaft on cloth.

– Unscrew nuts -2-.

– Loosen clamp -arrow-, and push it to rear.
– Detach catalytic converter with front exhaust pipe.

– Remove bolt -arrow- and push bracket for electrical wiring
harness to one side.
– Secure adapter T10359/3 to engine support -T10359-, as

shown in illustration.

– Use securing element -A- from gearbox support -3282- to

secure pin T10359/2 on engine support.
– Insert engine support -T10359- in engine and gearbox jack
-VAS 6931-.
– Fit engine support -T10359- to cylinder block. Screw bolt
-A- with spacer sleeve into cylinder block. Specified torque:
20 Nm.
– Secure engine with locking element -B-, and slightly lift en‐
gine with gearbox.
– Remove bolts -arrows- for engine mounting.

– Remove bolts -arrows- securing gearbox mounting.
– Carefully lower engine/gearbox assembly. Check that all

vacuum lines and electrical wiring between engine, gearbox
and body have been detached while doing so.

1.2 Separating engine and gearbox

⇒ e1.2.1 ngine and gearbox, vehicles with manual gearbox”,
page 29
⇒ e1.2.2 ngine and gearbox, vehicles with 7-speed dual clutch
gearbox”, page 32
1.2.1 Separating engine and gearbox, vehi‐

cles with manual gearbox
♦ Hook -10 - 222 A /2-
♦ Workshop hoist -VAS 6100-
♦ Lifting tackle -T40013-

Procedure
• Engine/gearbox assembly removed and attached to engine

bracket -T10359-.
– Release electrical wires from retainer -arrow- and lay them
to one side.
– Unscrew bolts -1 and 2-, and remove starter from gearbox.
– Move electrical wiring harnesses -1, 2- clear at air pipe.
– Loosen screw-type clip -3-.

– Remove bolts -arrows- and detach air pipe.
Unscrew bolts -arrows- and detach gearbox support.

– Attach lifting tackle -T40013- to gearbox and close lock.
Workshop hoist -VAS 6100- -1-

Hook -10-222A/2- -2-
Lifting tackle -T40013- -3-
– Remove bolts -1, 2, 3, 6, 7, 8, 9- securing gearbox to engine.
Note
Disregard -items 4, 5- and -A-.
– Pull gearbox off engine.

1.2.2 Separating engine and gearbox, vehi‐

cles with 7-speed dual clutch gearbox
♦ Engine bung set -VAS 6122-
NOTICE
Secondary damage due to damaged needle bearing.
– If engine and gearbox are separated, needle bearing in
crankshaft must be renewed ⇒ page 109 .
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket -T10497-.
– Remove starter ⇒ Electrical system; Rep. gr. 27; Starter;
Removing and installing starter.
– Unscrew coolant pipe from gearbox.
– Unscrew nuts -arrows-, and remove bracket at front of sump.
Note
The studs are welded to the front of the sump.

– Unscrew bolts -1, 2-, and remove bracket for bevel box.
Note
Use a cloth to catch the escaping coolant.
– Loosen hose clips -arrows- and remove coolant hoses from

gear oil cooler.
– Unscrew bolts -1 to 9- securing gearbox to engine.
Note
Disregard -item A-.

– Pull gearbox off engine.

– Before assembling, renew needle bearing in crankshaft ⇒
page 109 .
1.3 Securing engine on engine and gearbox support
Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-

♦ Workshop hoist -VAS 6100-
♦ Engine and gearbox support -VAS 6095-
Procedure
• Gearbox detached from engine ⇒ page 29 .
– Release catch -arrow-, and pull off left mounting -1- for en‐
gine cover panel.

– Unclip right mounting -1- for engine cover panel.
– Attach lifting tackle -2024 A- to engine on workshop hoist

-VAS 6100-.
– In order to match the lifting tackle to the centre of gravity of

the engine, the holes in the hook rail must be allocated as
shown in the illustration.
– The support hooks and pins on the lifting tackle must be
secured with locking pins -arrows-.
– Using workshop hoist -VAS 6100-, lift engine off engine and
gearbox jack -VAS 6931-.
– Remove dowel sleeves for gearbox, and, on gearbox side,
bolt engine to engine and gearbox support -VAS 6095-.

1.4 Installing engine

Procedure
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the correct type of hose
clips (same as original equipment) ⇒ Electronic parts cata‐
logue (ETKA).
♦ Fit all cable ties in the original position when installing.
– Check dowel sleeves for centring engine/gearbox and renew

if damaged.
– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.
– If clutch release bearing is worn, renew it ⇒ Rep. gr. 30;
Clutch mechanism; Repairing clutch release mechanism.
– Lightly grease input shaft splines using grease as per
⇒ Electronic parts catalogue (ETKA).
– Check centring of clutch plate.
– Bolt gearbox to engine.


– If engine and gearbox were separated, renew needle bear‐
ing in crankshaft ⇒ page 109 .

– Install bracket for bevel box.
– Install starter ⇒ Electrical system; Rep. gr. 27; Starter; Re‐
moving and installing starter.
– Guide engine/gearbox assembly into body.
– First screw bolts -arrows- for engine mountings into stop by
hand.
– First screw bolts -arrows- for gearbox mountings into stop by

hand.
– Adjust assembly mountings and tighten bolts ⇒ page 73 .

– Remove engine bracket -T10359- from engine.

– Install drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40; Drive shaft; Assembly overview - drive shaft.
– Install clutch slave cylinder ⇒ Rep. gr. 30; Clutch mecha‐
nism; Removing and installing clutch slave cylinder.
– Install cables with cable support bracket ⇒ Rep. gr. 34; Se‐
lector mechanism; Assembly overview - selector cables.
– Install and adjust selector lever cable ⇒ Rep. gr. 34; Selector
mechanism; Removing and installing selector lever cable.
– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
– Install poly V-belt ⇒ page 80 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27; Battery;
Assembly overview - battery.
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, elec‐
tronics boxes and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Install air filter housing ⇒ page 399 .
– Fit engine cover panel ⇒ page 76 .
– Check oil level.
– Connect coolant hoses with plug-in connector to heat ex‐
changer for heater ⇒ page 317 .
– Install subframe ⇒ Running gear, axles, steering; Rep.
gr. 40; Subframe; Removing and installing subframe without
steering rack.
– Install front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liner; Removing and
installing front wheel housing liner.
– Add coolant ⇒ page 282 .
If a new base engine or short engine was installed, additional
adaptations must be carried out in the engine control unit. Pro‐
ceed as follows to do this:
– Connect ⇒ Vehicle diagnostic tester, and select following
functions.
♦ 0001 - Engine electronics functions
♦ 0001 - Basic setting
♦ Timing chain length compensator, reset after re-
newing chain

Specified torques
Note
♦ The specified torques are only valid for nuts and bolts
which have been slightly greased, oiled, phosphate-treated
or black-oxided.
♦ Additional lubricant such as engine oil or gear oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for specified torques ± 15%.
Component Nm
Bolts and nuts M6 10
M7 15
M8 20
M10 40
M12 65
♦ Assembly mountings ⇒ o2.1 verview - assembly mountings”,
page 40 .
♦ Securing gearbox to engine ⇒ Rep. gr. 34; Removing and
installing gearbox; Specified torques for gearbox.

2 Assembly mountings
⇒ o2.1 verview - assembly mountings”, page 40
⇒ a2.2 nd installing engine mounting”, page 43
⇒ a2.3 nd installing gearbox mounting”, page 44
⇒ a2.4 nd installing pendulum support”, page 46
⇒ e2.5 ngine in installation position”, page 46
⇒ a2.6 djustment of assembly mountings”, page 73
⇒ a2.7 ssembly mountings”, page 73
2.1 Assembly overview - assembly mountings

1 - Engine support
❑ Removing and instal‐
ling ⇒ a1.6 nd installing
engine support”, page
92
2 - Bolt
❑ Renew after removal
❑ 10 Nm +90°
3 - Bolt
❑ 23 Nm
4 - Bracket
5 - Bolt
❑ Specified torque and
tightening sequence ⇒
Fig. ““Engine support
- specified torque and
installation sequence”“,
page 42
6 - Engine mounting
❑ With support arm
engine mounting”, page
43
7 - Bolt
❑ 23 Nm +90°
8 - Bolt
❑ 40 Nm +90°
9 - Earth cable
10 - Nut
❑ 9 Nm
11 - Bolt
❑ 60 Nm +90°
12 - Pendulum support
❑ Removing and installing ⇒ a2.4 nd installing pendulum support”, page 46
13 - Bolt
❑ Specified torque and tightening sequence ⇒ Fig. ““Installing pendulum support”“, page 42
14 - Bolt
15 - Bolt
16 - Bolt
2. Assembly mountings 41
❑ Specified torque ⇒ Gearbox; Rep. gr. 34; Assembly mountings; Assembly overview - assembly mount‐
ings
17 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ a2.3 nd installing gearbox mounting”, page 44
18 - Bolt
❑ Specified torque ⇒ Gearbox; Rep. gr. 34; Assembly mountings; Assembly overview - assembly mount‐
ings
Engine support - specified torque and installation sequence
• Renew bolts that are tightened with turning further angle

after each removal.
– Tighten bolts in stages in the sequence shown.
Stage Bolts Specified torque/turning further angle
1 -1 to 3- 7 Nm
2 -1 to 3- 40 Nm
3 -1 to 3- Turn 90° further
Installing pendulum support

after each removal.
1 -2, 3- 50 Nm
2 -1- 130 Nm

2.2 Removing and installing engine mount‐

ing
– Free hoses -2- from fittings and lay them to one side.
– Using a screwdriver, release fasteners -arrow- and move
coolant expansion tank to one side.
– Support engine in its installation position ⇒ page 46 .
– Tighten spindle slightly to take up weight of engine/gearbox
assembly; do not lift.
– Unscrew bolts -arrows- and remove engine mounting -1-.
Installing
Install in reverse order of removal, observing the following:
– Checking adjustment of assembly mountings ⇒ page 73 .
Specified torques
♦ ⇒ o2.1 verview - assembly mountings”, page 40
2.3 Removing and installing gearbox

mounting
Removing
– Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27;

Battery; Removing and installing battery tray.
– Remove engine control unit -J623- from bracket ⇒ page
425 .
– Unscrew nuts -arrows- and remove bracket -1-.
Note
Different types of brackets are fitted depending on version.
– Unclip wire guide -1- upwards -arrows-, and push it slightly

to one side.


– Unscrew bolts -2-. Then unscrew bolts -arrows-, and remove
gearbox mounting -1-.
Installing
Note
♦ Renew bolts that are tightened with turning further angle.

♦ Gearbox support and support arm of gearbox mounting must
be perfectly parallel to each other before screwing in bolts. If
necessary, lift gearbox at rear using trolley jack.
– Tighten gearbox mounting on longitudinal member.

– Lift gearbox with spindle of support bracket until gearbox
support makes contact with support arm of gearbox mount‐
ing.
– Start bolts by hand. Ensure to not screw in the bolts at an
angle while doing so.
– Checking adjustment of assembly mountings ⇒ page 73 .
– When the bolts are tightened to specified torque, remove
support bracket -10 - 222 A- from engine.
Specified torques
♦ Battery; Assembly overview - battery ⇒ Electrical system;
Rep. gr. 27; Battery; Assembly overview - battery
2.4 Removing and installing pendulum

support
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Unscrew bolts -1, 2, 3-, and remove pendulum support.
Installing
Specified torques
1 -2, 3- 60 Nm
2 -1- 130 Nm
♦ Noise insulation; Assembly overview - noise insulation
⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview - noise insulation
2.5 Supporting engine in installation posi‐

tion
⇒ e2.5.1 ngine in installation position, Golf”, page 46
⇒ e2.5.2 ngine in installation position, Tiguan”, page 52
⇒ e2.5.3 ngine in installation position, Arteon”, page 56
⇒ e2.5.4 ngine in installation position, Passat”, page 59
⇒ e2.5.5 ngine in installation position, T-Roc”, page 64
⇒ e2.5.6 ngine in installation position, Polo”, page 69
2.5.1 Supporting engine in installation posi‐

tion, Golf

♦ Support bracket -10 - 222 A-
♦ 2 x adapter -10 - 222 A /29-
♦ Adapter -10 - 222 A /18-
♦ Hook -10 - 222 A /20-
♦ Shackle -10 - 222 A /12-, qty. 2
♦ Square tube -T40091/1-
♦ Joints -T40091/3-
♦ Spindle -T40093/3-
♦ Adapter -T40093/3-6A-

Supporting engine

gine cover panel.
– Unclip right mounting -1- for engine cover panel from retain‐
er -2-.
– On both sides of vehicle, insert adapters -10 - 222 A /29-

between wing mounting flange and sheet metal for mounting
wing underneath it.
♦ Installation position:
“L” = -1- adapter is to be used on “right” side of vehicle (adapter
engages in recess of wing).
“R” (not shown in illustration), adapter is to be inserted on “left”

side of vehicle
Arrow -2- always points in direction of travel.
– Push adapter -10 - 222 A /18- and two connecting pieces
-T40091/3- onto support bracket -10-222 A-.
– Secure support bracket -10-222 A- to adapters -10 - 222 A /

29-.
– If present, pull off wires in front area of flange on both
longitudinal members -arrow-. Do not disconnect pipe/hose
system.
– Fit adapter -T40093/3-6A- to right longitudinal member as

– If necessary, carefully unclip any pipes for air conditioning
system in front area. Do not disconnect pipe/hose system
⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit;
System overview - refrigerant circuit.
– Fit adapter -T40093/3-6A- to left longitudinal member. If
present, it is directly behind filler pipe for washer fluid reser‐
voir -B-. If necessary, push adapter into correct position.

• Each of the adapters -T40093/3-6A- locks with pin -A- be‐

hind flange of longitudinal member -arrow-.
– Bolt on spindles -T40093 /3-.
– Connect spindles -T40093 /3- to support bracket -T40091/1-

using square tubes -10-222 A-, and tighten.
– Then, hook spindles into lifting eyes of engine. Use hook -10
- 222 A /20- and, if necessary shackle -10 - 222 A /12- for
this purpose.
– Take up weight of engine/gearbox assembly using spindles.
WARNING
Risk of injury due to improper handling of the support bracket.
Improper handling can lead to damage of the tool and subse‐
quent injuries.
– Never loosen and dismantle the engine and gearbox
mountings at the same time to avoid overloading of the
support bracket.

tion, Tiguan
♦ Hook -10-222A/10-
♦ Adapter -10-222A/28-
♦ Adapter -10-222A/28-2-
♦ 2 x adapter -10 - 222 A /29-

♦ -T40091/1- and -T40091/3- from engine support basic set

-T40091-, qty. 2
♦ Shackle -10 - 222 A /12-
Supporting engine
– Remove foam elements -arrows- for plenum chamber seal
on left and right.
– On both sides of vehicle, insert adapters -10 - 222 A /29- be‐

tween wing and sheet metal for mounting wing underneath
it.
Installation position:
♦ Support bracket -10-222 A- is set-up behind gas strut for
bonnet.
♦ Adapter “L” = -1- is inserted on “right” of vehicle.
♦ Adapter “R” (not seen here) is inserted on “left” of vehicle.
♦ Arrow -2- always points in direction of travel.
– Push 2 × swivel joints -T40091/3- onto support bracket
-10-222 A-.
– Secure support bracket -10-222 A- to adapters -10 - 222 A /
29-.
– Unscrew bolts -arrows- for lock carrier bracket on left and
right.
– Unscrew lower supports from adapters -10 - 222 A /28- and

replace them with adapters 10-222 A /28-2.

– Unscrew bolts -arrows- for securing support bracket to lock

carrier from adapter -10-222 A /28-2-.
– Bolt adapter -10-222 A /28-2- to lock carrier using securing
bolt -1-. Specified torque: 8 Nm.
– Set-up square tubes -T40091/1- with one spindle each as

shown.
– Engage spindles in support eyes of engine. Use shackle -10

- 222 A /12- if necessary.
WARNING
quent injuries.
support bracket.

tion, Arteon
♦ Adapter -10 - 222 A /8-
♦ Shackle -10 - 222 A /12- qty. 2

♦ Joints -T40091/3-
♦ Adapter -T40093/3-6A-
Supporting engine
on left and right.
Assemble engine support bracket -10-222 A- as shown:
A - Adapter -10 - 222 A /8-

B - Support bracket -10-222 A-
C - Square tube -T40091/1-
D - Connector -T40091/3-
E - Shackle -10 - 222 A /12-
F - Spindle -T40093/3- with adapter -T40093/3-6A-
– Place adapters -10 - 222 A /8- -A- on longitudinal member
behind bolt -arrow- on both sides of vehicle, as shown in
illustration.
– Place adapter -T40093/3-6A- on right longitudinal member.

• The adapter -T40093/3-6A- is locked with the pin -A- behind

the flange of the longitudinal member -arrow-.
WARNING
quent injuries.
support bracket.

tion, Passat
♦ Square tube -T40091/1-, qty. 2
♦ Connecting piece -T40091/3-, qty. 2

♦ Hook rail -T40091/2-
♦ Spindles -T40093 /3- qty. 2
♦ Swivel joints -T40093/4-, qty. 2

♦ 2 x adapter -T40093/3-6A-
♦ Hook -10 - 222 A /20-

♦ Shackle -10 - 222 A /12-
Supporting engine

gine cover panel.
– Unclip right mounting -1- for engine cover panel from retain‐
er -2-.

on left and right.
– Slide two connecting pieces -T40091/3- -(D)- onto support

bracket -B-.
– Fit support bracket -10-222 A- with feet -10-222A/1- -(A)- as

shown.
– Bolt spindles -T40093 /3- onto adapters -T40093/3-6A-.
– If present, pull off wires in front area of flange on both longi‐

tudinal members -arrow-.
– Fit adapter -T40093/3-6A- to right longitudinal member as

– Fit adapter -T40093/3-6A- to left longitudinal member. If

present, it is directly behind filler pipe for washer fluid reser‐
voir -B-. If necessary, push adapter into correct position.
• Each of the adapters -T40093/3-6A- locks with pin -A- be‐

hind flange of longitudinal member -arrow-.
– Slide swivel joints -T40093/4- onto square tubes -T40091/1-.
– Connect spindles -T40093 /3- and support bracket -10-222

A- using square section tubes -T40091/1-, and tighten them.
– Fit supports -T40091/2- to hook rail -T40093/5-.
– Connect hook rail -T40091/2- to square tubes -T40093/4-
using swivel joints -T40091/1-.
– Insert locking pin -1- into hook rail -T40091/2- and secure
with split pins.
– Then, hook spindles into lifting eyes of engine. Use hook -10
- 222 A /20- and, if necessary shackle -10 - 222 A /12- for
this purpose.
WARNING
quent injuries.
support bracket.

tion, T-Roc
♦ Adapter -10 - 222 A /35-
♦ Adapter -10-222A/18-

♦ Joints -T40091/3-
♦ Adapter -T40093/3-6A-
♦ Release tool -T10236-
Supporting engine
on left and right.

– Release and pull off connectors -1- and -2- on left longitudi‐
nal member.
– Release connector on retainer and unclip.

– Open locking element on retainer -arrow- on longitudinal
member.
– Expose wiring harness leading to engine control unit on
bracket.
– Expose positive wire to fuse carrier on bracket.
– Unclip wiring harness leading to engine control unit from
bracket and on battery tray. Use release tool -T10236- for
this.
– Lay wiring harnesses aside.
– Use release tool -T10236- to unclip bracket on longitudinal
member and swivel to right.
– Remove filler neck -1- at top on lock carrier -2-.

– To do this, release locking lug -3- in direction of -arrow-.

– Pull filler neck -1- upwards out of mounting.
– Fit adapter-T40093/3-6A- -A- to left longitudinal member.
– Guide adapter -T40093/3-6A- below filler pipe of washer flu‐

id reservoir.
– Place adapter -T40093/3-6A- onto left longitudinal member.
– Adapter -T40093/3-6A- must engage with pin -A- behind
web of longitudinal member -arrow-.
– If necessary, push adapter -T40093/3-6A- into correct posi‐
tion.
A - Adapter -10 - 222 A /35-

C - Adapter -10 - 222 A /18-
D - Connector -T40091/3-
E - Square tube -T40091/1-
F - Spindle -T40093/3- with adapter -T40093/3-6A-
illustration.

WARNING
quent injuries.
support bracket.

tion, Polo
♦ Adapter -10 - 222 A /13-
♦ Adapter -10-222A/32-
♦ Adapter -10-222A/16-
♦ Lifting tackle -2024A/1-
♦ Shackle -10-222A/12-
♦ Bracket -T10346-
Supporting engine
– Unbolt console for jump-start connection point -1- -arrows-
and fold aside.

A - Adapter -10 - 222 A /13-

C - Adapter -10-222A/32-
D - Adapter -10-222A/16-
E - Shackle -10 - 222 A /12-
illustration.
In addition, secure the engine support bracket -10-222 A- as

shown.
– Bolt bracket -T10346- -A- to rear right mounting hole for

battery tray.
– To do this, use a flange bolt M6 x 40 or a securing bolt for
battery tray.
– Fit tab -2024 A/ 1- -B- as shown and secure with pin -arrow-.
– Attach tab -B- with a shackle -C- on adapter -D-.
– Take up weight of spindle of adapter -10-222A/16-.
– Take up weight of engine/gearbox assembly using spindles
of adapter -10-222A/32-.
WARNING
quent injuries.
support bracket.

2.6 Checking adjustment of assembly

mountings
Procedure
The following specifications must be obtained:
• There must be a distance of -a- = 10 mm between engine

support -2- and engine mounting -1-.
• Side surface of engine support casting should be located
parallel to support arm of engine mounting.
• Distance -b- = distance -b-.
Note
Distance -a- = 10 mm can be checked with a metal rod of

suitable size, or similar.
– If the dimension is too small or too high, adjust assembly

mountings ⇒ page 73 .
2.7 Adjusting assembly mountings

Procedure
– Remove battery tray -1- ⇒ Electrical system; Rep. gr. 27;

Battery; Removing and installing battery tray.
– Unscrew engine mounting bolts -arrows- one after the other
and renew them (if not already renewed when installing en‐
gine).
– First screw bolts in loosely.

– Using assembly lever, adjust engine/gearbox assembly until
specifications listed below are attained:
• There must be a distance of -a- = 10 mm between engine

support -2- and engine mounting -1-.
• Side surface of the engine support casting should be located
parallel to support arm of engine mounting.
• Distance -b- = distance -b-.
Note
Distance -a- = 10 mm can be checked with a metal rod of

suitable size, or similar.
– Tighten bolts for engine mounting.

– Unscrew gearbox mounting bolts -arrows- one after the oth‐
er and renew them (if not already renewed when installing
engine).

– First screw bolts in loosely.

– On gearbox side, ensure that support arm and gearbox
mounting are parallel.
• Distance -x- = distance -x-.

– Tighten bolts for gearbox mounting.
Specified torques
♦ ⇒ Electrical system; Rep. gr. 27; Battery; Assembly overview
- battery
3 Engine cover panel

⇒ a3.1 nd installing engine cover”, page 76
3.1 Removing and installing engine cover

Removing
– Carefully pull engine cover panel off ball studs one after
other -arrows-. Do not pull off engine cover panel abruptly or
only on one side (image shows example).
Installing
– To prevent damage, do not strike engine cover panel with
your fist or a tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel onto ball studs, first on left and
then on right.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ o1.1 verview - cylinder block (pulley end)”, page 77
⇒ a1.2 nd installing poly-V belt”, page 80
⇒ a1.3 nd installing tensioner for poly V-belt”, page 81
⇒ a1.4 nd installing vibration damper”, page 81
⇒ a1.5 nd installing bracket for ancillaries”, page 89
⇒ a1.6 nd installing engine support”, page 92
1.1 Assembly overview - cylinder block (pulley end)
1. Cylinder block (pulley end) 77

1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Poly V-belt routing ⇒
Fig. ““Poly V-belt rout‐
ing”“, page 79
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen
poly-V belt”, page 80
❑ When installing, make
sure it is properly seat‐
ed on poly V-belt pul‐
leys.
2 - Bolt
❑ 20 Nm +90°
3 - Bolt
❑ 100 Nm +180°
4 - O-ring
❑ Included in items sup‐
plied ⇒ Item 3 (page
78) ; not available sep‐
arately
5 - Vibration damper
❑ With poly V-belt pulley
vibration damper”, page
81
6 - Ancillary bracket
❑ With oil filter housing and engine oil cooler
❑ Removing and installing ancillary bracket ⇒ a1.5 nd installing bracket for ancillaries”, page 89 .
❑ Removing and installing engine oil cooler ⇒ a2.2.1 nd installing engine oil cooler”, page 261
7 - Seal
8 - O-ring
❑ Moisten with coolant
9 - Connection
10 - O-ring
11 - Bolt
❑ Specified torques and tightening sequence ⇒ Fig. ““Ancillary bracket - specified torques and tightening
sequence”“, page 79
12 - Alternator
78 Rep. gr.13 - Crankshaft group

❑ Assembly overview ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
13 - Bolt
❑ Specified torque ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator
14 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87; Air conditioner compressor;
Removing and installing air conditioner compressor from and to bracket
15 - Bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Assembly over‐
view - drive unit of air conditioner compressor.
16 - Dowel sleeves
17 - Tensioning device
❑ for poly V-belt
❑ Removing and installing ⇒ a1.3 nd installing tensioner for poly V-belt”, page 81
Poly V-belt routing
1- Vibration damper
2- Tensioning device for poly V-belt
3- Alternator
4- Air conditioner compressor
Ancillary bracket - specified torques and tightening sequence


after each removal.
– Fit ancillary bracket (start bolt -4- first).
– Tighten bolts -1 to 5- in stages in the sequence shown:
Stage Specified torques/angle specifications
1 Screw in by hand as far as stop
2 20 Nm
3 Turn 90° further
1.2 Removing and installing poly-V belt

♦ Locking pin -T10060A-
Removing
CAUTION
Danger of injury; the radiator fan can run at any time.
– When working in vicinity of radiator, maintain safe distance
from fan.
NOTICE
Risk of irreparable damage to poly V-belt that has already
been used by reversing direction of rotation.
– Mark direction of rotation before removing.
– Observe direction of rotation when re-installing.
– To relieve tension of poly V-belt, turn tensioner clockwise

-arrow-.
– Use the locking pin -T10060A- to lock the tensioner.

– Remove poly V-belt.

Installing
– Fit poly V-belt ⇒ Fig. ““Poly V-belt routing”“, page 79 .
– Turn tensioning device slightly in clockwise direction -arrow-
and pull out locking pin -T10060A-.
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
1.3 Removing and installing tensioner for

poly V-belt
Removing
• Use locking pin -T10060A- to lock tensioner ⇒ a1.2 nd instal‐
ling poly-V belt”, page 80 .
– Unscrew bolt -2-.
– Remove tensioner -1-.

Installing
Install in reverse order of removal.
Specified torques
♦ ⇒ o1.1 verview - cylinder block (pulley end)”, page 77
1.4 Removing and installing vibration

damper
♦ Counter-hold tool -T10355-

♦ Assembly tool -T10531-
♦ Adapter -T10531/5-
♦ Ratchet wrench AF21 -T40263-
♦ Adapter -T40314-
♦ Tensioning pin -T10531/6-

♦ The vibration damper securing bolt -A- is used to secure
the vibration damper -1- and the timing chain sprocket -2-
on crankshaft -3-. Before unscrewing the securing bolt, lock
the timing chain sprocket in position relative to crankshaft as
described below:

Removing
insulation.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Wheel housing liner; Assembly
overview - front wheel housing liner.
-arrow-.
– Remove poly V-belt and relieve tensioner.
NOTICE
Risk of damage to engine when the drive chain slips.
– Only turn engine in direction of engine rotation.
– Turn crankshaft with ratchet ring spanner AF 21 -T40263-,

adapter -T40314- and socket AF 24 until vibration damper is
at “TDC”.

• Notch -1- on vibration damper must align with arrow marking

-2- on bottom timing chain cover.
• Marking on bottom timing chain cover is located at »4 o'clock
position«
• Vibration damper bolt may only be loosened maximum 1/2
turn initially.
– Loosen vibration damper bolt approx. 1/2 turn using counter

hold tool -T10355- -item 1-.
– If vibration damper was turned while loosening bolt, reset
“TDC” position.
– Unscrew bolts -arrows- for lower timing chain cover.
– Screw adapter -T10531/5- finger-tight into cylinder block.

– Position support -T10531/1- on vibration damper as shown

and screw knurled screws -1, 3- into adapters finger-tight.
– If necessary, align adapters on hexagon socket -2- with hex‐
agon key AF 4 and counterhold.
• Arrow marking on support -T10531/1- must point upwards.
– Unscrew vibration damper bolt completely.
– Check if turning over tool -T10531/3- -item A- slides easily
over clamping pieces -B-. Unscrew tensioning bolt -arrow-
slightly if necessary.
• Do not turn the tensioning bolt any more, otherwise the

clamping pin -T10531/6- will be jammed when it is screwed
into the crankshaft.
– Screw clamping pin -T10531/6- into crankshaft, and tighten it
finger-tight with a 12 mm open-end spanner -item A-.
– Tighten tensioning bolt -A- by hand in order to lock the chain

sprocket in position relative to crankshaft.
– Unscrew knurled screws -arrows-. Remove support -

T10531/1- and vibration damper -A-.

Turning crankshaft without vibration damper
– Fit turning over tool -T10531/3- -A- on clamping pin -

T10531/6-. Pay attention to toothed contours of chain
sprocket when doing so.
• In TDC position the flat section of the tool faces upwards.
– Tighten turning over tool with flange nut -T10531/4- -B-.
– Crankshaft can now be turned on hexagon -arrow-.

Installing

• Renew bolt with O-ring after removal.
– If necessary, remove flange nut -T10531/4- -B- and turning
over tool -T10531/3- -A- from clamping pin -T10531/6-.
– Fit vibration damper in TDC position. Pay attention to teeth
of chain sprocket -arrow- while doing so.
– Fit turning over tool -T10531/3- -A- on clamping pin -

T10531/6-.
• The hexagon faces the vibration damper.

– Screw on flange nut -T10531/4- -B-. Move vibration damper
slightly back and forth while doing so to ensure that vibration
damper is properly seated on teeth.
– Tighten flange nut until vibration damper can no longer be
turned.
– Position support -T10531/1- on vibration damper as shown
and screw knurled screws -1, 3- into adapters finger-tight.

– If necessary, align adapters on hexagon socket -2- with hex‐

agon key AF 4 and counterhold.
• Arrow marking on support -T10531/1- must point upwards.
– Loosen flange nut -T10531/4- -item A- and clamping pin -B-.
– Unscrew clamping pin -T10531/6-, and remove it together

with turning over tool -T10531/3-.
– Screw in new vibration damper bolt with lubricated O-ring -1-
by hand.
– Unscrew knurled screws -1, 3- and remove support -

T10531/1-.

– Unscrew adapter -T10531/5-.

– Tighten vibration damper bolt using counterhold tool -
T10355- -item 1-.
Further installation is carried out in reverse order of removal,

observing the following:
• Renew bolts for timing chain cover after removal.
– Install poly V-belt ⇒ a1.2 nd installing poly-V belt”, page 80 .
Specified torques
♦ ⇒ o2.1 verview - cover for timing chain”, page 157
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Noise insula‐
tion; Assembly overview – noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liner; Assembly overview- front wheel housing liner.
1.5 Removing and installing bracket for an‐

cillaries

Removing
– Remove engine cover panel ⇒ a3.1 nd installing engine cov‐
er”, page 76 .
– Drain coolant ⇒ c1.3.1 oolant”, page 281 .
– Remove poly V-belt ⇒ a1.2 nd installing poly-V belt”, page
80 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27; Alterna‐
tor; Removing and installing alternator.
– Remove oil filter element ⇒ o1.2 il:”, page 252 .
– Separate electrical connectors and free off electrical wiring:
1- For oil pressure switch -F22-

2- For oil pressure switch for reduced oil pressure -F378-
3- For piston cooling jet control valve -N522-
– Unscrew bolts -arrows-, and remove bracket -1-.
– Free off retaining clip -2- for wiring harness.


– Unclip guide tube for oil dipstick from timing chain cover
(top) -arrow-.
– Move electrical wiring clear.
– Place a cloth underneath ancillary bracket for any engine oil

that escapes.
– Unscrew bolts -1 to 5- and detach bracket for ancillary units
from coolant pump housing.
Installing
after each removal.
• Renew O-rings, seals and gaskets after each removal.
• Never reuse old coolant.
– Moisten new O-rings -4- with coolant.

– Insert connector -2- in actuator for engine temperature regu‐

lation -N493- -item 3-.
– Push engine oil cooler -1- with bracket for ancillaries onto
connection. Start bolts then tighten to specified torque.
– Install oil filter element and check oil level ⇒ o1.2 il:”, page
252 .
– Install alternator ⇒ Electrical system; Rep. gr. 27; Alternator;
Removing and installing alternator.
– Add coolant ⇒ w1.3.2 ith coolant”, page 282 .
– Fit engine cover panel ⇒ a3.1 nd installing engine cover”,
page 76 .
Specified torques
♦ ⇒ Fig. ““Ancillary bracket - specified torques and tightening
1.6 Removing and installing engine sup‐

port
Removing
– Unscrew bolts -2, 3- for pendulum support.

– Removing engine mounting ⇒ a2.2 nd installing engine

mounting”, page 43 .
– Separate electrical connector -1- for oil pressure switch -
F22-.
– Unscrew bolts -arrows-, and remove bracket -1-.
– Raise engine with spindle -10-222A/11- until respective bolt

of engine support is accessible.

– Unscrew bolts -1, 2 and 3-, and remove engine support.

Installing
after each removal.
– Fit bolt -2- into hole in engine support before inserting en‐
gine support.
– Bring engine support into position and screw in bolts -1, 2, 3-
as far as stop by hand and then tighten to specified torque
and in tightening sequence.
– Install engine mounting ⇒ a2.2 nd installing engine mount‐
ing”, page 43 .
– Install oil filter element ⇒ o1.2 il:”, page 252 .
Specified torques
♦ ⇒ o1.1 verview – silencers”, page 437

2 Cylinder block, gearbox end

⇒ o2.1 verview - cylinder block, gearbox end”, page 95
⇒ a2.2 nd installing flywheel”, page 97
⇒ a2.3 nd installing sealing flange on gearbox side”, page 99
2.1 Assembly overview - cylinder block, gearbox end
1 - Adapter
❑ Do not damage or bend
when assembling.
ling ⇒ Fig. ““Removing
and installing adapter
plate”“, page 96
2 - Dowel sleeves
3 - Sealing flange, gearbox
side
❑ With seal
sealing flange on gear‐
box side”, page 99
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Do not remove guide
sleeve until sealing
flange has been push‐
ed onto crankshaft jour‐
nal.
4 - Bolt
Fig. ““Sealing flange,
gearbox end - specified
torque and tightening
5 - Adapter
❑ Installed depending on
version
❑ Removing and installing ⇒ Fig. ““Removing and installing adapter plate”“, page 96
6 - Bolt
❑ 25 Nm
7 - Flywheel
❑ Removing and installing ⇒ a2.2 nd installing flywheel”, page 97
❑ Can only be fitted in one position
8 - Bolt
❑ 60 Nm +90°
2. Cylinder block, gearbox end 95

Removing and installing adapter plate
Removing
• Engine and gearbox separated ⇒ e1.2 ngine and gearbox”,
page 29 or gearbox removed ⇒ Gearbox; Rep. gr. 34; Re‐
moving and installing gearbox; Installing gearbox.
– Unscrew bolt -arrow-.
– Remove intermediate plate -1- from dowel sleeves.
Installing
Removing and installing adapter plate
Removing
• Flywheel removed ⇒ a2.2 nd installing flywheel”, page 97 .
• Intermediate plate removed ⇒ Fig. ““Removing and installing
adapter plate”“, page 96 .
– Pull off intermediate plate from dowel sleeves
-bottom arrows- and detach at sealing flange -top arrow-.
Installing
– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.
Sealing flange, gearbox end - specified torque and tightening
sequence


Stage Specified torque
2 9 Nm
2.2 Removing and installing flywheel

♦ Counter-hold tool -3067-
Removing
• Gearbox is removed.
NOTICE
Risk of damaging flywheel.
– Unscrew bolts by hand. Do not use pneumatic wrenches or
other power impact wrenches.
– When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.
– Insert counter-hold tool -3067- in hole on cylinder block

-item B-, loosen bolts for flywheel.

– Unscrew bolts -2-, and detach flywheel -1-.
Installing
NOTICE
Oil may start to escape if threaded holes in crankshaft are not
cleaned or not cleaned properly.
– Clean threaded holes in crankshaft of adhesive residue
and locking fluid.
– Make sure not to damage oil seal when cleaning.
– Clean crankshaft flange until adhesive and locking fluid resi‐

due is removed completely.
– Vacuum off loosened particles of locking fluid residue using
industrial vacuum cleaner – never blow them out with com‐
pressed air.
– Use commercially available wire brush to completely remove
any sealant residue from one of the flywheel bolts which was
unscrewed during removal.
– Screw the cleaned bolt -2- in and out the threaded hole of
crankshaft -1- until no more locking fluid residue comes out.

– During the cleaning process, permanently hold an industrial

vacuum cleaner at the threaded connection in order to col‐
lect the locking fluid residue that comes out.
– Repeat cleaning process for all threaded holes of crankshaft.
– Remove oil residue using commercially available oil dissolv‐
ing agent.
– Use a cloth to clean the flange of the crankshaft. Crankshaft
threads must be free of oil and grease.
NOTICE
Risk of damaging flywheel.
– Mount flywheel in such a way that bolts align centrally with
holes.
– Screw in bolts by hand. Do not use pneumatic wrenches or
other power impact wrenches.
– Screw in bolts for flywheel as far as stop in diagonal se‐

quence.
– Insert counter-hold tool -3067- in hole in cylinder block -A-
and tighten bolts.
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 95
2.3 Removing and installing sealing flange

on gearbox side

♦ Fitting tool -T10122C-
♦ Hand drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic Parts Catalogue
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34; Removing and
installing gearbox; Removing gearbox.
– Remove intermediate plate ⇒ Fig. ““Removing and installing
– Unscrew bolts -1 … 8-.
– Detach sealing flange from adhesive bond.

– Cover open parts of engine.
Installing
• Renew sealing flange after removal.

CAUTION
Risk of eye injury caused by sealant residue.
– Remove sealant remaining on cylinder block -1- with flat

scraper or rotating plastic brush.
– Remove any oil and grease from sealing surfaces.
• Check sealing flange; it must be free of kinks and damage.
• The sealing lip must face engine following installation. If

the sealing lip »folds out« during installation, oil leaks may
occur.
– Check guide -T10122/6A- -item B-. It must be clean and free
of sharp edges.
– Fit fitting tool -T10122/1- -item A- on guide.

– Push sealing flange -C-, leading with outer side, onto guide.
– Remove fitting tool.
• Observe use-by-date of sealant.

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

2 mm).
Please note:
Illustration does not show guide -T10122/6A-.
NOTICE
Risk of damage to engine due to excess sealant in lubrication
system.
– Do not apply sealant bead thicker than specified.
• Thickness of sealant bead: 2 to 3 mm.

• Install the sealing flange within 5 minutes after the sealant
has been applied.
– Place guide -T10122/6A- -item A- with sealing flange -B- on
crankshaft journal.
Please note:
It is not necessary to tighten the bolts -arrows-.

– Carefully move sealing flange -B- over guide -A- and bring
into installation position, paying attention to centring shoul‐
der on left and right when doing this.
– Remove guide.
– Bolt on sealing flange.
• Perform a visual inspection after installing to determine
whether the sealing lip has folded over or is otherwise dam‐
aged.
• Allow sealant to cure for approx. 30 minutes after installing
sealing flange. Only then fill with engine oil.
– Install intermediate plate ⇒ Fig. ““Removing and installing
– Check oil level ⇒ o1.2 il:”, page 252 .
Specified torques
♦ ⇒ o2.1 verview - cylinder block, gearbox end”, page 95

3 Crankshaft
⇒ o3.1 verview - crankshaft”, page 104
⇒ d3.2 imensions”, page 107
⇒ o3.3 f main bearing shells”, page 107
⇒ n3.4 eedle bearing in crankshaft”, page 109
⇒ a3.5 xial clearance of crankshaft”, page 112
⇒ r3.6 adial clearance of crankshaft”, page 113
⇒ a3.7 nd installing crankshaft”, page 114
⇒ a3.8 nd installing sender wheel”, page 116
3.1 Assembly overview - crankshaft

• For assembly work, secure engine to engine and gearbox
support ⇒ e1.3 ngine on engine and gearbox support”, page
34 .

1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove.
❑ Renew worn bearing
shells
❑ Marking of crankshaft
bearing shells (classifi‐
cation) ⇒ o3.3 f main
bearing shells”, page
107
❑ Lubricate with engine
oil
3 - Crankshaft
❑ After removing, place
it down so that the
sender wheel ⇒ Item 8
(page 106) is not dam‐
aged and the crank‐
shaft does not rest on
the sender wheel
❑ If the crankshaft is
renewed, the bearing
shells must be reallo‐
cated to bearing cap
⇒ o3.3 f main bearing
shells”, page 107
❑ Measuring axial clear‐
ance ⇒ a3.5 xial clear‐
ance of crankshaft”,
page 112 .
❑ Measuring radial clear‐
ance ⇒ r3.6 adial clear‐
ance of crankshaft”,
page 113
❑ Crankshaft dimensions
⇒ d3.2 imensions”, page 107 .
4 - Bearing shell for bearing cap
❑ Without oil groove.
❑ Renew worn bearing shells
❑ Marking of crankshaft bearing shells (classification) ⇒ o3.3 f main bearing shells”, page 107
❑ Lubricate with engine oil
5 - Bolt
❑ Use old bolts to measure radial clearance.
❑ Specified torque and tightening sequence ⇒ Fig. ““Crankshaft - specified torques and tightening
6 - Bearing cap
❑ Bearing cap 1: belt pulley end.
❑ Bearing caps 2, 3, 4 screwed on side in addition
❑ Mark installation position for re-installation ⇒ Fig. ““Marking of crankshaft bearing caps”“, page 106
7 - Bolt
❑ Sender wheel ⇒ Item 8 (page 106) must be renewed each time bolts are loosened ⇒ a3.8 nd installing
sender wheel”, page 116
3. Crankshaft 105
❑ 10 Nm +90°
8 - Sender wheel
❑ For engine speed sender -G28-
❑ Can only be fitted in one position
❑ Sender wheel ⇒ Item 7 (page 105) must be renewed each time bolts are loosened
❑ Removing and installing ⇒ a3.8 nd installing sender wheel”, page 116
❑ Adaptations are necessary after this component has been renewed ⇒ d3.2 iagnoses”, page 6
9 - Thrust washers
❑ For bearing 3
10 - Bolt
❑ Specified torques and tightening sequence ⇒ Fig. ““Crankshaft - specified torques and tightening
Crankshaft - specified torques and tightening sequence

after each removal.
Stage Bolts Specified torques/angle specifica‐
tions
1 -1 to 10- and Screw in by hand as far as stop
-arrows-
2 -1 to 10- 65 Nm
4 -Arrows- 15 Nm
5 -Arrows- Turn 90° further
Marking of crankshaft bearing caps

– Mark installation position of bearing caps -1 … 5- for rein‐

stallation.
• Tabs -arrows- on bearing caps must face towards crankshaft
bearing “3” on inlet side.
3.2 Crankshaft dimensions

Honing dimension Crankshaft bearing Conrod bearing
1) journal diameter journal diameter
mm mm
LK1, LK2 ⇒ page 4 48.00 -0,032 47.80 -0,022
-0.052 -0.042
LK3 ⇒ page 4 52.00 -0,032
-0.052
1)There is currently no provision for worn crankshafts to be
reconditioned.
3.3 Allocation of main bearing shells

Bearing shells of the correct thickness are allocated to the cylin‐
der block and crankshaft in the factory. Coloured dots are used
to identify the thickness of the bearing shells.
Which bearing shell is to be inserted at each place in the cylin‐
der block (upper bearing shell) is marked by letters on the lower
sealing surface or on the front side of cylinder block.
Which bearing shell is to be inserted at each place in bearing
cap (lower bearing shell) is marked by letters on the crankshaft.
The first letter is allocated to bearing cap one, the second to
bearing cap two, etc.
3. Crankshaft 107
Marking on bearing shell for cylinder block:
The marking on the cylinder block can be found engraved either

in the sump sealing surface or in the front end (gearbox side) of
the cylinder block.
Identification on cylinder block is allocated to upper bearing
shell (bearing shell for cylinder block).
– Note letter and identify colour code to be installed based on

table.
S = black
R = red
G = yellow
B = blue
V = violet
W = white

Marking on bearing shell for bearing cap:
Identification on crankshaft is allocated to lower bearing shell

(bearing shell for bearing cap).
– Note letter and identify colour code to be installed based on
table.
R = red
G = yellow
B = blue
W = white
V = violet
S = black
3.4 Renewing needle bearing in crankshaft

♦ Pin -VW207C-
3. Crankshaft 109
♦ Counter support -VAS 251 621-
♦ Internal puller -VAS 251 635-
Condition:
• Always renew needle bearing -arrow- after separating en‐

gine and dual clutch gearbox.
• The front edges of the inner puller must be free of chips.

Pulling out needle roller bearing
– The internal puller must be positioned behind the needle-

and-cage assembly -top arrow-.
– Pull out needle bearing -1- with internal puller -VAS 251
635- -A- and counter support -VAS 251 621- -item B- from
crankshaft -2-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of

grease.
– Drive needle bearing into crankshaft to installation depth us‐
ing drift -VW207C-.
Installation depth: dimension -a- = 2.0 mm
3. Crankshaft 111
• If the needle bearing is inadvertently driven in too far, it must

be renewed because it will be damaged when it is pulled out
again.
3.5 Measuring axial clearance of crank‐

shaft
♦ Universal dial gauge holder -VW387-
♦ Dial gauge -VAS 6079-

Procedure
– Screw dial gauge -VAS 6079- with universal dial gauge hold‐
er -VW387- onto cylinder block and set against crank web.
– Press crankshaft against dial gauge by hand and set gauge
to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.070 to 0.231 mm
• Wear limit: 0.30 mm.
3.6 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
• Use old bolts to measure radial clearance.
• Renew worn bearing shells.
– Remove crankshaft bearing caps ⇒ a3.7 nd installing crank‐
shaft”, page 114 .
– Clean bearing cap and bearing journal.
– Place a length of Plastigage corresponding to the width of
the bearing on the bearing journal or bearing shell.
• The Plastigage must rest in the middle of the bearing shell.
– Fit crankshaft bearing cap and tighten using old bolts
-1 … 10- ⇒ Fig. ““Crankshaft - specified torques and tight‐
ening sequence”“, page 106 . Make sure not to rotate crank‐
shaft while tightening.
3. Crankshaft 113
– Remove crankshaft bearing cap again.

– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.017 to 0.037 mm
– Renew bolts for final assembly.
3.7 Removing and installing crankshaft

♦ Puller -T10055-
Removing
• Engine removed and secured to engine and gearbox support
⇒ e1.3 ngine on engine and gearbox support”, page 34 .
– Remove top section of sump ⇒ a1.5 nd installing upper part
of sump”, page 254 .
– Remove drive chain for balance shaft ⇒ a3.6 nd installing
drive chain for balance shaft”, page 202 .
– Mark installation position and allocation of conrod bearing
caps -1- to conrods ⇒ Item 2 (page 127) .

– Unscrew bolts -arrows- and remove coolant conrod bearing

cap.
• Do not damage industrially cracked surfaces of conrod and
conrod bearing cap.
– Remove bolts -arrows- and bolts -1 to 10-.
– Pull off bearing cap using puller -T10055-.
3. Crankshaft 115
– Remove crankshaft.
Installing
– Install drive chain for balance shaft ⇒ a3.6 nd installing drive
chain for balance shaft”, page 202 .
– Install upper part of sump ⇒ a1.5 nd installing upper part of
sump”, page 254 .
Specified torques
♦ ⇒ o3.1 verview - crankshaft”, page 104
3.8 Removing and installing sender wheel

Removing
– Remove crankshaft ⇒ a3.7 nd installing crankshaft”, page
114 .
– Unscrew sender wheel.
Installing
– Renew sender wheel -2- each time bolts -1- are loosened.
♦ The second time the bolts are tightened, the contact points
in the sender wheel for the countersunk heads are deformed
so much that the bolt heads seat on the crankshaft -3-,
-arrows- and the sender wheel is loose under the bolts.
♦ The sender wheel can only be installed in one position, the
holes are offset.
Adjustments must be made after renewing sender wheel ⇒
d3.2 iagnoses”, page 6 .
– Install crankshaft ⇒ a3.7 nd installing crankshaft”, page 114 .
Specified torques

4 Balancer shaft
⇒ o4.1 verview - balance shaft”, page 117
⇒ a4.2 nd installing balance shaft”, page 119
4.1 Assembly overview - balance shaft
4. Balancer shaft 117

1 - Cylinder block
2 - Bolt
❑ 9 Nm
3 - Balance shaft, inlet side
❑ Lubricate bearing with
engine oil
❑ Always renew in pairs
⇒ a4.2.1 nd installing
balance shaft, inlet
side”, page 119
4 - Pipe
❑ For balance shaft, ex‐
haust side
❑ 136 mm long
❑ Fitting position ⇒ Fig.
““Tube for balancer
shaft - installation posi‐
tion”“, page 118
5 - Bolt
❑ 9 Nm
6 - Balance shaft, exhaust
side
❑ Lubricate bearing with
engine oil
❑ Always renew in pairs
⇒ a4.2.2 nd installing
balance shaft, exhaust
side”, page 122
7 - Needle bearing
❑ Observe colour of gear
ring for needle bearing;
always install needle
bearing of corresponding colour
❑ Lubricate bearing with engine oil
❑ Firmly press together needle-cage assembly during installation until it engages
8 - Needle bearing
❑ Observe colour of gear ring for needle bearing; always install needle bearing of corresponding colour
❑ Lubricate bearing with engine oil
❑ Firmly press together needle-cage assembly during installation until it engages
9 - Pipe
❑ For balance shaft, inlet side
❑ 123 mm long
❑ Fitting position ⇒ Fig. ““Tube for balancer shaft - installation position”“, page 118
10 - Seal
❑ Renewing ⇒ o4.2.3 il seal for balance shaft (inlet side)”, page 124
Tube for balancer shaft - installation position

• Tab -arrow A- on balance shaft must engage in recess

-arrow B- on tube.
4.2 Removing and installing balance shaft

⇒ a4.2.1 nd installing balance shaft, inlet side”, page 119
⇒ a4.2.2 nd installing balance shaft, exhaust side”, page 122
⇒ o4.2.3 il seal for balance shaft (inlet side)”, page 124
4.2.1 Removing and installing balance shaft,

inlet side
Removing
– Remove toothed belt for coolant pump ⇒ a2.7 nd installing
toothed belt for coolant pump”, page 299 .
• Observe direction of rotation: bolt of drive sprocket has left-
hand thread - risk of thread damage.

– Detach drive sprocket -1- for toothed belt for coolant pump.
– Unscrew bolt -1- and remove intermediate shaft gear.

– Remove bearing mounting -1-.
– Unscrew bolt -2- and pull out balance shaft on inlet side. If
necessary, turn balance shaft slightly to do this.
Installing
• After removing balance shaft, needle bearing must be re‐
newed.
• Observe colour of gear ring for needle bearing; always install
needle bearing crown of corresponding colour.
• Renew intermediate gear after removal.
after each removal.
– Push on tube, observe correct installation position when
doing so ⇒ Fig. ““Tube for balancer shaft - installation posi‐
tion”“, page 118 .
– Firmly press together needle-cage assembly of new needle
bearing until it engages.

– Check that all rollers in bearing cage are inserted correctly.

– Apply engine oil on bearing and contact surface of bearing
-arrows- on balance shaft, inlet side.
– Turn balance shaft to installation position.

• When installing, make sure that half-round contact surface of
bearing points upwards.
– Insert balance shaft on inlet side and tighten bolt -2-.
– Lubricate new O-ring -1- with engine oil.
– Coat bearing mounting with engine oil and insert.

• Dowel pin -arrow- for bearing mounting must engage in bore
in cylinder block.
NOTICE
Risk of irreparable damage to engine if there is no tooth back‐
lash.
– Renew intermediate gear.

Please note:
The new idler gear is coated with a solid film lubricant that
wears off after a short period and thus automatically sets the
tooth backlash.
– Mark faces of gear teeth of idler gear with paint -arrow-.
– Insert idler gear; marking on balance shaft must be posi‐

tioned between markings on faces of gear teeth.
– Tighten bolt -1- for intermediate gear in this gear position:
tightening sequence ⇒ Fig. ““Intermediate gear - specified
torque and tightening sequence”“, page 172 .
– Check markings on idler gear/balance shaft -arrow-.

– Renew oil seal for balance shaft on inlet side ⇒ o4.2.3 il seal
for balance shaft (inlet side)”, page 124 .
– Fit toothed belt for coolant pump ⇒ a2.7 nd installing toothed
belt for coolant pump”, page 299 .
Specified torques
♦ ⇒ o4.1 verview - balance shaft”, page 117
4.2.2 Removing and installing balance shaft,

exhaust side
Removing
– Unscrew bolt -1- and pull out balance shaft on exhaust side.

Installing
• After removing balance shaft, needle bearing must be re‐
newed.
• Observe colour of gear ring for needle bearing; always install
needle bearing crown of corresponding colour.
• Renew intermediate gear after removal.
after each removal.
– Push on tube, observe correct installation position when
doing so ⇒ Fig. ““Tube for balancer shaft - installation posi‐
tion”“, page 118 .
– Firmly press together needle-cage assembly of new needle
bearing until it engages.
– Check that all rollers in bearing cage are inserted correctly.
– Apply engine oil on bearing and contact surface of bearing
-arrows- on balance shaft, exhaust side.
– Turn balance shaft to installation position.

• When installing, make sure that half-round contact surface of
bearing points upwards.
– Insert balance shaft on exhaust side and tighten bolt -1-.


Specified torques
♦ ⇒ o4.1 verview - balance shaft”, page 117
4.2.3 Renewing oil seal for balance shaft (in‐

let side)
♦ Thrust piece -T10353/1-
Procedure
– Remove toothed belt for coolant pump ⇒ a2.7 nd installing
toothed belt for coolant pump”, page 299 .
– Unscrew bolt -2- and remove drive sprocket -1- for coolant
pump toothed belt.

– Press screwdriver -1- firmly onto section -2- of seal

-arrow B-.
– Lever out seal -arrow A-.

– Clean contact surface and sealing surface.
– Lubricate sealing surface of balance shaft -2- with gear oil.
– Fit seal -1- onto balance shaft.

• Lettering “Inside” -arrow- must point towards engine.
– Position thrust piece -T10353/1- on seal -1- and carefully

press into cylinder block as far as stop using bolt -2- (ensure
seal is seated properly).
– Fit toothed belt for coolant pump ⇒ a2.7 nd installing toothed
belt for coolant pump”, page 299 .

5 Pistons and conrods

⇒ o5.1 verview - pistons and conrods”, page 126
⇒ a5.2 nd installing pistons”, page 131
⇒ a5.3 nd installing oil spray jets”, page 134
⇒ p5.4 istons and cylinder bores”, page 136
⇒ n5.5 ew conrod”, page 138
⇒ r5.6 adial clearance of conrods”, page 138
5.1 Assembly overview - pistons and conrods

1 - Bolts
❑ Apply engine oil to
thread and contact sur‐
face
❑ Use old bolts to meas‐
ure radial clearance.
❑ 45 Nm +90°
2 - Conrod bearing cap
❑ Observe installation po‐
sition
❑ Conrod bearing cap on‐
ly fits in one position
and only on the appro‐
priate conrod due to
the cracking procedure
separating the cap from
the conrod
❑ Mark allocation to cylin‐
der and conrod in col‐
our -A-
❑ Installation position:
cast sections -B- point
towards pulley end
❑ Separating new conrod
⇒ n5.5 ew conrod”,
page 138 .
3 - Bearing bushes
““Bearing shell installa‐
tion position ”“, page
128
❑ Allocation ⇒ Fig.
““Bearing shell alloca‐
tion”“, page 128
❑ Renew worn bearing shells
❑ Apply engine oil before installing
❑ Axial clearance
♦ New: 0.10 to 0.35 mm
♦ Wear limit: 0.40 mm
❑ Measuring radial clearance ⇒ r5.6 adial clearance of conrods”, page 138
4 - Connecting rod
❑ Renew as set only.
❑ Mark allocation to cylinder and to conrod bearing cap -A-
❑ Installation position: cast sections -B- point towards pulley end
❑ Separating new conrod ⇒ n5.5 ew conrod”, page 138 .
❑ Measuring radial clearance ⇒ r5.6 adial clearance of conrods”, page 138
5 - Pressure relief valve
❑ 27 Nm
6 - Oil spray jet
❑ For piston cooling
❑ Installation position
♦ ⇒ Fig. ““Oil spray jets for LK1/LK2 - installation position”“, page 130
5. Pistons and conrods 127

♦ ⇒ Fig. ““Oil spray jets for LK3 - installation position”“, page 131
❑ Removing and installing ⇒ a5.3 nd installing oil spray jets”, page 134
7 - Retaining ring
8 - Piston pin
❑ Apply engine oil before installing
9 - Piston
❑ Removing and installing ⇒ a5.2 nd installing pistons”, page 131
❑ Installation position: arrow on piston crown faces towards pulley end
❑ Mark allocation to cylinder
❑ Checking piston and cylinder bore ⇒ p5.4 istons and cylinder bores”, page 136
10 - Compression rings
❑ Install using piston ring pliers -VAS 211 003- ⇒ Fig. ““Installing compression rings”“, page 129
❑ Allocation and installation position ⇒ Fig. ““Allocation of piston rings”“, page 129
❑ Checking ring gap ⇒ Fig. ““Checking piston ring gap”“, page 137 .
❑ Ring-to-groove clearance not measurable.
❑ Offset gaps by 120°
11 - Oil scraper ring
❑ Carefully remove and install three-part oil scraper ring by hand
❑ Install in such a way that upper gap of three-part oil scraper ring is offset by 120° relative to adjacent
compression ring
❑ Ring gap cannot be measured
❑ Ring-to-groove clearance not measurable.
❑ Fitting position ⇒ Fig. ““Installing oil scraper ring”“, page 130
❑ Allocation ⇒ Fig. ““Allocation of piston rings”“, page 129
Bearing shell allocation
1- Bearing shell for conrod bearing cap: two white strips

2- Bearing shell for conrod bearing cap: one white strip
Bearing shell installation position

– Position bearing shells in centre of conrod and conrod bear‐

ing cap when fitting.
• Distance -a- = distance -a-.
Allocation of piston rings
1- Compression ring with chamfer -A- at top inside to upper

groove. »TOP« marking and lettering point upwards.
2- Compression ring with shoulder -A- at bottom outside
to centre groove. »TOP« marking and lettering point up‐
wards.
3- Oil scraper ring
Installing compression rings

• »TOP« marking and lettering point upwards.

• Compression ring -2- should not be opened any further than
necessary to just push it over piston -1-. Use piston ring
pliers -VAS 211 003- to do so.
Installing oil scraper ring
– Note installation position of spring:

• Butts of plates -2, 3- and spring -1- must have an offset of at
least 90° to each other.
• Install by hand.
Installation sequence:
– 1 Insert spring -1- into groove.
– 2) Insert plate -3- in bottom of groove.
– 3) Insert plate -2- in top of groove.
Oil spray jets for LK1/LK2 - installation position

LK1/LK2 ⇒ page 4
• Side surface of oil spray jet -1- must be aligned parallel to
adjacent crankshaft bearing -2-.
• Distance -a- = distance -a-.
Oil spray jets for LK3 - installation position
LK3 ⇒ page 4
• Dowel pin -2- for oil spray jet must engage in bore -1- in
cylinder block.
5.2 Removing and installing pistons


♦ Pin -VW222A-
♦ Funnel -T40347-
Removing
• Engine secured to engine and gearbox support ⇒ e1.3 ngine
on engine and gearbox support”, page 34 .
– Remove cylinder head ⇒ a1.2 nd installing cylinder head”,
page 144 .
– Mark installation position and association:
♦ Piston to cylinder.
♦ Conrod to cylinder ⇒ Item 4 (page 127) .
♦ Conrod bearing cap to conrod ⇒ Item 2 (page 127) .
cap -1-.

conrod bearing cap.
– Withdraw piston upwards together with conrod.

Please note:
If the piston pin is difficult to move, heat the piston to approx.

60°C.
– Remove retaining ring -2- from piston pin eye.
– Drive out piston pin -3- using drift -VW222A-.
– Remove piston -1- from conrod -4-.
Installing
after each removal.
• Arrow on piston crown points to belt pulley end.
• Install in such a way that upper gap of three-part oil scraper
ring is offset by 120° relative to adjacent compression ring.
– Install compression rings ⇒ Fig. ““Installing compression
rings”“, page 129 .
– Install oil scraper ring ⇒ Fig. ““Installing oil scraper ring”“,
page 130 .
– Oil contact surfaces of bearing shells and cylinder walls with
engine oil.
– Carefully push piston -1- into cylinder -arrow- by hand using

funnel -T40347-.
– Install conrod bearing cap, noting installation position ⇒ Item
2 (page 127) .
– Install cylinder head ⇒ a1.2 nd installing cylinder head”,
page 144 .
sump”, page 254 .

Specified torques
♦ ⇒ o5.1 verview - pistons and conrods”, page 126
5.3 Removing and installing oil spray jets

♦ Insert tool -T10545-
Removing cylinders “1” to “3”:


NOTICE
– Turn crankshaft on vibration damper with ratchet ring span‐

ner AF 21 -T40263-, adapter -T40314- and socket AF 24
-arrow- until relevant bolt is accessible.
Removing cylinder “4”:
– Remove crankshaft ⇒ a3.7 nd installing crankshaft”, page
114 .
Continued for all cylinders:
– Unscrew pressure relief valve -1- using socket -T10545-.

– Remove oil spray jet -2- (image shows example).
Installing
Installation position
• ⇒ Fig. ““Oil spray jets for LK1/LK2 - installation position”“,
page 130
• ⇒ Fig. ““Oil spray jets for LK3 - installation position”“, page
131
NOTICE
Risk of damage to oil spray jets caused by deformation.
– Do not bend oil spray jets.
– Install crankshaft ⇒ a3.7 nd installing crankshaft”, page 114 .


sump”, page 254 .
Specified torques
♦ ⇒ o5.1 verview - pistons and conrods”, page 126
5.4 Checking pistons and cylinder bores

♦ Micrometre 75 - 100 mm -VAS 6071-
♦ Cylinder gauge -VAS 6078-, not shown

Checking piston
– Measure pistons approx. 15 mm from lower edge of skirt, at

90° to piston pin axis, using micrometer 75 - 100 mm -VAS
6071-.
♦ Maximum deviation from nominal dimension: 0.04 mm.
Piston diameter, mm
Specification 82.4201)
• 1)Dimensions without coating (thickness 0.02 mm) The
coating will wear down.
Checking cylinder bores

• Do not measure cylinder bores when cylinder block is moun‐

ted on engine and gearbox support as measurements may
be incorrect.
NOTICE
Risk of damage to the surface of the cylinder bore caused by
incorrect machining.
– Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Measure at 3 points -c-, in longitudinal direction -a- and lat‐

eral direction -b-, using cylinder gauge -VAS 6078-.
♦ Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore diameter, mm
Specification 82.511)
• Measure depth of cylinder bore 1) in 50 mm.
Checking piston ring gap
– Push piston ring at right angles to cylinder wall from above

down to approx. 15 mm from bottom end of cylinder. Push in
using a piston without rings.
Piston ring New Wear limit
mm mm
1 compression ring 0.30 to 0.40 0.60

Piston ring New Wear limit

mm mm
2 compression ring 0.40 to 0.50 0.70
Oil scraper ring Cannot be measured
5.5 Separating new conrod

On a new conrod, it is possible that the breaking point has not
been fully separated. Proceed as follows if the conrod bearing
cap cannot be removed by hand:
– Mark the cylinder to which the conrod belongs ⇒ Item 4
(page 127) .
– Clamp conrod -1- in a vice below the dashed line using
aluminium vice clamps.
• Only clamp the conrod lightly in order to avoid damaging it.

– Unscrew both bolts -2- about 5 turns.
– Using a plastic hammer, carefully knock against conrod
bearing cap -1- in direction of -arrow- until it is loose.
5.6 Checking radial clearance of conrods

♦ Plastigage
Procedure
– Mark installation position and allocation of conrod bearing
caps -1- to conrods ⇒ Item 2 (page 127) .


cap.
conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a length of Plastigage corresponding to the width of
the bearing on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten it using old bolts ⇒ Item
1 (page 127) . When tightening, make sure not to rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance
• New: 0.02 to 0.06 mm
– Renew bolts for final assembly.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ o1.1 verview - cylinder head”, page 140
⇒ a1.2 nd installing cylinder head”, page 144
⇒ a1.3 nd installing vacuum pump”, page 153
⇒ c1.4 ompression”, page 154
1.1 Assembly overview - cylinder head
140 Rep. gr.15 - Cylinder head, valve gear

1 - Cylinder head gasket

❑ Renewing ⇒ a1.2 nd in‐
stalling cylinder head”,
page 144
❑ Installation position:
part number facing to‐
wards cylinder head
❑ Renew coolant and en‐
gine oil after replacing.
❑ Adaptations are neces‐
sary after this compo‐
nent has been renewed
⇒ d3.2 iagnoses”, page
6
2 - Bolt
❑ 10 Nm +90°
3 - Engine lifting eye
4 - Partition
5 - Bolt
❑ 10 Nm +90°
6 - Engine lifting eye
7 - Cylinder head
cylinder head”, page
144
❑ Check for distortion ⇒
Fig. ““Checking cylinder
head for distortion”“,
page 143 .
❑ Observe pair number of
cylinder head cover and cylinder head ⇒ Fig. ““Pair number of cylinder head cover and cylinder head”“,
page 143
❑ Renew coolant and engine oil after replacing.
❑ Adaptations are necessary after removing and installing or renewing ⇒ d3.2 iagnoses”, page 6
8 - Bolt
❑ Loosening ⇒ Fig. ““Loosening cylinder head bolts”“, page 142
❑ Specified torque and tightening sequence ⇒ Fig. ““Cylinder head - specified torque and tightening
9 - Bolt
❑ 20 Nm
10 - Bracket
❑ For pressure differential sender for particulate filter -G1037-
11 - Heat shield
12 - Bolt
❑ 8 Nm
13 - Nut
❑ 8 Nm
1. Cylinder head 141

14 - Nut
❑ 8 Nm
15 - Bolt
❑ 10 Nm
16 - Plug
❑ 20 Nm
17 - Bolt
❑ 9 Nm
18 - Union
❑ For coolant hose
19 - O-ring
20 - Bolt
❑ Loosening ⇒ Fig. ““Loosening cylinder head bolts”“, page 142
❑ Specified torques and tightening sequence ⇒ Fig. ““Cylinder head - specified torque and tightening
21 - O-ring
22 - Union
❑ For coolant hose
23 - Bolt
❑ 9 Nm
24 - Dowel pin
❑ Qty. 2
Loosening cylinder head bolts

– Loosen cylinder head bolts in the sequence -1 to 10- and
unscrew.
Cylinder head - specified torque and tightening sequence


after each removal.
tions
1 -1 to 10- Screw in by hand as far as stop
2 -1 to 10- 50 Nm
5 -Arrows- 8 Nm
6 -Arrows- Turn 90° further
Pair number of cylinder head cover and cylinder head
Each cylinder head cover is uniquely paired to a cylinder head

with this pair number.
• Both eight-digit numbers -arrows- must match: XXXXXXXX
= XXXXXXXX.
• Make absolutely sure during installation that the allocation is
correct.
Checking cylinder head for distortion

– Use straight edge 500 mm -VAS 6075- and feeler gauge to

measure cylinder head for distortion at several points.
♦ Max. permissible distortion: 0.05 mm
Vacuum pump - tightening specified torque
– Tighten bolts -arrows- for vacuum pump -1- to 9 Nm.
1.2 Removing and installing cylinder head

♦ Spark plug socket -3122B-

♦ Spring-type clip pliers -VAS 6362-
♦ Scraper (blade width at least 40 mm), commercially availa‐

ble
Removing
• Fit all cable ties in the original position when installing.

• Cover openings in gearbox with a cloth to prevent any cool‐

ant finding its way into clutch housing.
– Remove camshafts ⇒ a4.2 nd installing camshaft”, page
215 .
– Remove connector -arrow- for Lambda probe 1 after cata‐
lytic converter -GX7- from retainer, disconnect and free off
electrical wire.
– Unscrew bolts -arrows- and remove connection -1-.
– Release hose clip -arrow- and remove air intake hose.
– Release hose clips -2- and detach hoses.

– Unscrew bolt -1- and free off control lines.

– Remove Lambda probe 1 before catalytic converter -GX10-
⇒ a9.2 nd installing Lambda probe”, page 435 .
– Unscrew bolt -1- and remove screw-type clip.
– Loosen bolt -2-, detach catalytic converter at top and push to

one side (shown with engine removed).
– Unscrew bolts -arrows- and nuts -1- and remove heat shield.
– Remove front coolant pipe ⇒ a3.2.1 nd installing front cool‐

ant pipe”, page 309 .
– Lift retaining clip -1- and disconnect coolant hose.

– Disconnect connectors:
1- For throttle valve module -GX3-

2- For intake manifold sender -G71-.
– Free off wiring harness and push to one side.
them.
– Separate electrical connectors -4, 5-.

– Unscrew bolts -1- on bracket.

2 - For oil pressure switch for reduced oil pressure -F378-

3 - For piston cooling jet control valve -N522-
– Release hose clip -1- and detach rear coolant hose.
– Free off coolant hoses.

– Disconnect connector -2- for coolant temperature sender -
G62-.
– Free off coolant hoses.
– Unscrew bolts -arrows- and push oil supply line -1- to one
side.
– Unscrew bolts -arrows-, pull off coolant connection -1- and
oil return line -2-.

– Disconnect connector -1- for charge pressure control module

-GX34- and lay aside.
– Remove spark plugs using spark plug socket and extension

-3122B-.

– Use special wrench -T40270- to remove cylinder head bolts

in the sequence -1 to 10-.
– Check that all hose and pipe connections are loose.
CAUTION
The cylinder head is heavy and may cause an accident.
– Seek help from a second a mechanic for the following
work.
– Remove cylinder head.

– Place cylinder head onto soft surface (foam plastic).
– Seal open channels of intake and exhaust system with clean
cloths or with thoroughly cleaned plugs from engine bung set
-VAS 6122-.
Installing
NOTICE
Risk of damage to sealing surfaces from improper handling.
– Carefully remove sealant residue from cylinder head and
cylinder block.
• Do not use sandpaper, grinding wheels, abrasive or scour

pads or any other sanding or abrasive media.
• The sealing surface must not project.
• Discolourations like dark spots do not need to be removed.
• When removing the sealant residue, make sure no loose

particles get into the open channels of the engine.
• Ensure that all adjacent workspaces are clean, and that
none of the above mentioned sanding or abrasive media are
used.
• Using unauthorised sanding or abrasive media may lead to
secondary damage such as, for example, damage to the
turbocharger or the conrod bearings.
CAUTION
– Do not use any other means rather than a standard blade

scraper (at least 40 mm wide) to remove the sealant residue
from the cylinder head and cylinder block.
– Remove any loose remains using a lint-free cloth.


after each removal.
• Renew self-locking nuts as well as seals, gaskets and O-
rings after each removal.
• Check O-ring in crankcase breather hose for damage ⇒
o3.1 verview - crankcase breather system”, page 263 .
• Secure all hose connections with hose clips corresponding
to the series equipment ⇒ Electronic parts catalogue.
• Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
• When installing an exchange cylinder head, the plastic pro‐
tectors fitted to protect the open valves should not be re‐
moved until the cylinder head is ready to be fitted.
• If installing an exchange cylinder head, lubricate contact sur‐
faces between roller rocker finger and cam with oil before
installing cylinder head cover.
• When cylinder head or cylinder head gasket is replaced, all
the coolant must be replaced and engine oil changed.
– Clean blind holes for cylinder head bolts in cylinder block of
oil and coolant residue.
– Position cylinder head gasket.
♦ Note dowel pins in cylinder block -arrows-.

♦ Check installation position of cylinder head gasket. Charac‐
teristic: the part number should be legible from the inlet side.
– If crankshaft was turned in the meantime, position no. 1
cylinder piston at top dead centre and then turn crankshaft
90° again in anti-clockwise direction out of “TDC” position.
– Fit cylinder head with the aid of a second mechanic.
– Insert cylinder head bolts, and tighten them by hand.
– Bolt tightening sequence for cylinder head ⇒ Fig. ““Cylinder
head - specified torque and tightening sequence”“, page 142
Please note:
After repair work it is not necessary to retighten the cylinder
head bolts.
– Install spark plugs ⇒ o1.1 verview - ignition system”, page
492 .

– Install front coolant pipe ⇒ a3.2.1 nd installing front coolant

pipe”, page 309 .
– Install catalytic converter ⇒ page 475 .
– Install Lambda probe 1 before catalytic converter -GX10- ⇒
a9.2 nd installing Lambda probe”, page 435 .
– Install camshafts ⇒ a4.2 nd installing camshaft”, page 215 .
– Change engine oil ⇒ o1.2 il:”, page 252 .
– Connect coolant hoses with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“, page 317 .
– Fill cooling system with fresh coolant ⇒ page 282 .
Adaptations are necessary after removing and installing or re‐
newing the cylinder head ⇒ d3.2 iagnoses”, page 6 .
Specified torques
♦ ⇒ o1.1 verview - cylinder head”, page 140
♦ ⇒ o5.1 verview – intake manifold”, page 404
♦ ⇒ o9.1 verview - Lambda probe”, page 433
♦ ⇒ o1.1 verview – turbocharger”, page 337
♦ ⇒ o2.2 verview - charge-air hose connections”, page 362
1.3 Removing and installing vacuum pump

Removing
– Remove high-pressure pump ⇒ a8.2 nd installing high-pres‐
sure pump”, page 430 .
– Remove vacuum hose -2- from vacuum pump -1-, pressing
release buttons on both sides to do so.
– Remove bolts -arrows- and detach vacuum pump.

Installing
• Renew seal after each removal.
– Ensure seal is installed in correct installation position.
– Position follower of vacuum pump -1- so that it engages in
slot of camshaft when vacuum pump is fitted -arrows-.

– Installing high-pressure pump ⇒ a8.2 nd installing high-pres‐

Specified torques
♦ ⇒ Fig. ““Vacuum pump - tightening specified torque”“, page
144
1.4 Checking compression

♦ Compression tester -V.A.G 1763-
♦ Adapter -V.A.G 1763/13-, not illustrated

Test sequence
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.7 V.
er”, page 76 .
– Separate connector -arrow- for injectors.

– Remove ignition coils ⇒ a1.2 nd installing ignition coils”,

page 494 .
– Unscrew spark plugs using spark plug socket and extension
-3122B-.
– Screw in adapter -V.A.G 1763/13- into the corresponding

spark plug hole and connect the compression tester -V.A.G
1763-.
– Check compression pressure using compression tester -

V.A.G 1763-; refer to ⇒ Operating instructions.
– Have a second mechanic press down accelerator completely
and simultaneously operate starter until pressure no longer
increases on tester display.
– Repeat procedure on each cylinder.

Compression pressures bar

New 16.0 to 19.0
Wear limit 12.0
Maximum difference between cylinders 3.0
Installing
492 .
– Install ignition coils ⇒ a1.2 nd installing ignition coils”, page
494 .
page 76 .
– In engine control unit, clear any event entries which may
have been stored during the test ⇒ Vehicle diagnostic tester.

2 Cover for timing chain

⇒ o2.1 verview - cover for timing chain”, page 157
⇒ a2.2 nd installing timing chain cover”, page 160
⇒ s2.3 eal for vibration damper”, page 165
2.1 Assembly overview - cover for timing chain
2. Cover for timing chain 157

1 - O-ring
oil
2 - Dipstick guide tube
3 - Bolt
❑ Self-locking
❑ Clean threaded hole for
bolt with, for example, a
thread tap
❑ 9 Nm
4 - Not installed
5 - Bolt
❑ Captive, included ⇒
Item 13 (page 158)
❑ Specified torques and
Fig. ““Upper timing
chain cover - specified
torque and tightening
6 - Bolt
❑ Self-locking
❑ Clean threaded hole for
bolt with, for example, a
thread tap
❑ 8 Nm +45°
7 - Inlet camshaft control
valve 1 -N205-
ling ⇒ a4.4 nd installing camshaft control valves N205/N318”, page 234
8 - Bolt
❑ Self-locking
❑ Clean threaded hole for bolt with, for example, a thread tap
❑ 8 Nm +45°
9 - Exhaust camshaft control valve 1 -N318-
❑ Removing and installing ⇒ a4.4 nd installing camshaft control valves N205/N318”, page 234
10 - Oil seals
❑ Renew if damaged or leaking
❑ Installation position: small inner diameter points outwards
❑ To replace, remove upper timing chain cover ⇒ Item 13 (page 158)
11 - Seal
12 - Cap
13 - Timing chain cover (top)
❑ Removing and installing ⇒ a2.2.1 nd installing upper timing chain cover”, page 160

14 - Seal
15 - O-ring
❑ Installed depending on power class
❑ Moisten with engine oil
16 - Dowel pin
❑ Qty. 2
❑ For lower timing chain cover
17 - Bolt
❑ Self-locking
❑ Clean threaded hole for bolt with, for example, a thread tap
❑ Specified torques and tightening sequence ⇒ Fig. ““Lower timing chain cover - specified torque and
tightening sequence”“, page 159
18 - Lower timing chain cover
❑ With seal
❑ Removing and installing ⇒ l2.2.2 ower timing chain cover”, page 162
19 - Seal
❑ For vibration damper
❑ Renewing ⇒ s2.3 eal for vibration damper”, page 165
20 - Plug
Upper timing chain cover - specified torque and tightening se‐

quence

Stage Specified torques
2 9 Nm
Lower timing chain cover - specified torque and tightening se‐
quence


after each removal.
tions
2 -1 to 15- 8 Nm
3 -1, 2, 4, 5- and Turn 45° further
-7 to 15-
4 -3, 6- Turn 45° further after installing vibra‐
tion damper
2.2 Removing and installing timing chain

cover
⇒ a2.2.1 nd installing upper timing chain cover”, page 160
⇒ l2.2.2 ower timing chain cover”, page 162
2.2.1 Removing and installing upper timing

chain cover
Removing
– Remove engine support ⇒ a1.6 nd installing engine support”,
page 92 .
– Remove camshaft adjustment valves ⇒ a4.4 nd installing
camshaft control valves N205/N318”, page 234 .
– Release hose clip -2-, disconnect coolant hose and push
towards right.


(top) -arrow-.
– Move electrical wiring clear.
– Unscrew bolts -1…6- and remove upper timing chain cover.

Installing
• Renew seals and gasket if damaged or leaking.
• Renew O-rings after removal.
– Lubricate seals and O-rings with engine oil.
• Installation position of seals: small inner diameter points out‐
wards.
– Install camshaft adjustment valves ⇒ a4.4 nd installing cam‐
shaft control valves N205/N318”, page 234 .

– Installing engine support ⇒ a1.6 nd installing engine sup‐

port”, page 92 .
Specified torques
♦ ⇒ Fig. ““Upper timing chain cover - specified torque and
2.2.2 Removing lower timing chain cover

Due to the adhesive strength of the sealant, the lower timing
chain cover is deformed as it is removed. For this reason, the
cover always needs to be renewed.
Removing
• Engine oil drained ⇒ o1.2 il:”, page 252
page 92 .
– Remove front right wheel housing liner ⇒ General body re‐
overview - front wheel housing liner.
-arrow-.
– Remove poly V-belt and relieve tensioner.


(top) -arrow-.

– Remove vibration damper ⇒ a1.4 nd installing vibration

damper”, page 81 .
– Separate electrical connector -1- for valve for oil pressure
control -N428-.
– Lever off lower timing chain cover from adhesive.

Installing
after each removal.
• Renew lower timing chain cover and seal after removal.
– Cover open parts of engine.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Check that both dowel pins -arrows- for centring the cover
are fitted.


3 mm).
NOTICE
system.
– Apply sealant -1- to clean sealing surface and to edges -2-

of new cover.
• Thickness of sealant bead: 2 to 3 mm.

• The cover must be installed within 5 minutes of applying

sealant.
– Install cover immediately, and tighten bolts ⇒ Fig. ““Low‐
er timing chain cover - specified torque and tightening se‐
quence”“, page 159 .
• Allow sealant to dry for approx. 30 minutes after installing
cover. Only then fill with engine oil.
– Install vibration damper ⇒ a1.4 nd installing vibration damp‐
er”, page 81 .
– Installing engine support ⇒ a1.6 nd installing engine sup‐
port”, page 92 .
– Replenish engine oil and check oil level ⇒ o1.2 il:”, page
252 .
Specified torques
♦ ⇒ Fig. ““Lower timing chain cover - specified torque and
2.3 Renewing seal for vibration damper

♦ Thrust piece -T10354-
♦ Thrust plate -T10375-

♦ Flange nut -T10531/4- from assembly tool -T10531-
♦ Extractor hook -T40274-
Removing
– Remove vibration damper ⇒ a1.4 nd installing vibration

damper”, page 81 .
– Using extractor hook -T40274-, pull out seal -arrow-.
– Clean contact surface and sealing surface.
– Slide seal -arrow- onto thrust piece -T10354-.

• Closed side of oil seal faces towards thrust piece -T10354-.

– Slide seal -arrow- with thrust piece -T10354- onto clamping
pin -T10531/6- -item 1- and position on lower timing chain
cover.
– In addition, fit thrust pad -T10375-, and screw in flange nut

-10531/4-.
– Drive in oil seal to stop using thrust piece -T10354-.

Installing
– Install vibration damper ⇒ a1.4 nd installing vibration damp‐
er”, page 81 .

3 Chain drive
⇒ o3.1 verview - camshaft timing chains”, page 168
⇒ o3.2 verview - drive chain for balance shaft”, page 170
⇒ a3.3 nd installing camshaft timing chain”, page 173
⇒ a3.4 nd installing bearing saddle”, page 196
⇒ t3.5 iming chain”, page 201
⇒ a3.6 nd installing drive chain for balance shaft”, page 202
3.1 Assembly overview - camshaft timing chains

1 - Tensioning rail
❑ for camshaft timing
chain
2 - Bolt
❑ 9 Nm
3 - Chain tensioner
❑ Is spring-loaded
❑ Secure with locking tool
-T40435- before remov‐
ing
4 - Guide pin
❑ 20 Nm
5 - Bolt
❑ Tightening sequence ⇒
Fig. ““Bearing saddle
- specified torque and
tightening sequence”“,
page 170
6 - Clamping sleeve
7 - O-ring
❑ Installed depending on
power class
oil
8 - Timing valve
❑ Left-hand thread
❑ Checking ⇒ Fig.
““Checking control
valve”“, page 170
❑ 35 Nm
9 - O-ring
❑ Installed depending on power class
10 - Bearing saddle
❑ Removing and installing ⇒ a3.4 nd installing bearing saddle”, page 196
11 - Slide rail
❑ for camshaft timing chain
12 - Cylinder head cover
13 - Camshaft timing chain
❑ For re-installation, mark running direction with paint.
❑ Removing and installing ⇒ a3.3 nd installing camshaft timing chain”, page 173
❑ After working on chain drive, adaptations must be carried out ⇒ d3.2 iagnoses”, page 6
14 - Slide rail
❑ for camshaft timing chain
15 - Guide pin
❑ 20 Nm
3. Chain drive 169

16 - Triple chain sprocket

❑ Fitting position ⇒ Fig. ““Triple chain sprocket - installation position”“, page 170
Bearing saddle - specified torque and tightening sequence

2 9 Nm
Triple chain sprocket - installation position
• The two sections -arrows- must be aligned.

Checking control valve
• It should be possible to press in piston -1- approx. 3 mm

against spring force. It must move freely, without sticking.
3.2 Assembly overview - drive chain for balance shaft

1 - Triple chain sprocket

““Triple chain sprocket
- installation position”“,
page 170
2 - Guide pin
❑ 20 Nm
3 - Tensioning rail
❑ For drive chain for bal‐
ance shaft
4 - Drive chain for balance
shaft
drive chain for balance
shaft”, page 202
5 - Guide pin
❑ 20 Nm
6 - Balance shaft, exhaust
side
❑ Assembly overview ⇒
o4.1 verview - balance
shaft”, page 117
7 - Chain tensioner
❑ Use sealant to install
⇒ Electronic parts cata‐
logue
❑ 85 Nm
8 - Seal
❑ Not available as a sep‐
arate part; included in
scope of supply ⇒ Item
7 (page 171)
9 - Cylinder block
❑ Assembly overview ⇒ o4.1 verview - balance shaft”, page 117
11 - O-ring
12 - Bearing mounting
❑ Fitting position ⇒ Fig. ““Bearing mounting - installation position”“, page 172
13 - Intermediate gear
❑ If bolt ⇒ Item 15 (page 171) has been loosened, intermediate gear must be renewed
14 - Thrust washer
15 - Bolt
❑ If bolt has been loosened, intermediate gear ⇒ Item 13 (page 171) must be renewed
❑ Specified torques and tightening sequence ⇒ Fig. ““Intermediate gear - specified torque and tightening
3. Chain drive 171

16 - Slide rail
❑ For drive chain for balance shaft
17 - Guide pin
❑ 12 Nm
18 - Slide rail
❑ For drive chain for balance shaft
19 - Guide pin
❑ 20 Nm
Bearing mounting - installation position
– Lubricate new O-ring -1- with engine oil before installing.

• Dowel pin -arrow- for bearing mounting must engage in bore
in cylinder block.
– Lubricate bearing mounting with engine oil.
Intermediate gear - specified torque and tightening sequence

after each removal.
– Tighten bolt in stages.
1 10 Nm
2 – Turn intermediate gear
• There must be no play in intermediate gear;

otherwise loosen bolt and tighten again
3 25 Nm
4 Turn 90° further

3.3 Removing and installing camshaft tim‐

ing chain
⇒ a3.3.1 nd installing camshaft timing chain, DNPA, DNFC,
DNFE, DNFG, DSFE, DRNA, DSFB, DSFF”, page 173
⇒ a3.3.2 nd installing camshaft timing chain, DNNA, DNND”,
page 184
3.3.1 Removing and installing camshaft

timing chain, DNPA, DNFC, DNFE,
DNFG, DSFE, DRNA, DSFB, DSFF
♦ Lever -T40243-
♦ Ratchet ring spanner, 21 mm -T40263-
3. Chain drive 173

♦ Camshaft clamp -T40271/1 und /2-
♦ Locking tool -T40435-
Removing
– Remove bearing saddle ⇒ a3.4 nd installing bearing saddle”,
page 196 .

NOTICE
– Turn crankshaft on vibration damper with ratchet ring span‐

ner AF 21 -T40263-, adapter -T40314- and socket AF 24
until vibration damper is at “TDC”.
• Marking -3- on camshaft sprockets -2- and -4- must point
upwards respectively.
• Notch -arrow- on vibration damper -1- must align with arrow

mark -5- on lower timing chain cover.
– Remove lower timing chain cover ⇒ l2.2.2 ower timing chain
cover”, page 162 .
– Check “TDC position” again.
– Detach retaining clip of tensioning spring -3- on top section
of sump -arrow-.
3. Chain drive 175

– Unscrew guide pin -2- and remove chain tensioner.

– Remove drive chain -1- for oil pump from three-stage chain
sprocket and allow to hang on clamping pin -T10531/6-.
– Bolt lever -T40243- to cylinder head -bottom arrows-.
– Press together retaining ring -1- of chain tensioner and hold

it in that position.
– Slowly push lever -T40243- in direction of -arrow- and hold it
in that position.
• This will compress the chain tensioner.

Please note:
The chain tensioner is oil-damped and can therefore only be
compressed slowly by applying constant pressure.
– Lock chain tensioner with special tool -T40435-.
– Remove lever -T40243-.

– Bolt clamp -T40271/2- onto cylinder head.
– Insert camshaft clamp between teeth of chain sprocket

-arrow B-.
– If necessary, use adapter -T40427- to slightly turn inlet cam‐
shaft back and forth -arrows A-.
– Bolt clamp -T40271/1- onto cylinder head.
• A second mechanic is required for the following work step.

– Hold exhaust camshaft with assembly tool -T40427-. Re‐
move guide pin -1- and remove tensioning rail -2- down‐
wards.
3. Chain drive 177

– Turn exhaust camshaft further in clockwise direction

-arrow A- until clamp -T40271/1- can be inserted in teeth
of sprocket -arrow B-.
– Release catch -arrow- with a screwdriver and push guide rail
-1- off forwards.
– Unscrew guide pins -1-, and remove guide rail -2-.
– Remove camshaft timing chain from camshaft sprockets,

and remove it downwards.
NOTICE
Risk of damage to engine if valves strike piston crowns.
– Do not turn crankshaft any further when camshaft timing
chain is removed.

Installing
Prerequisites:
• Crankshaft is positioned at “TDC”; V recess on three-stage
sprocket points along imaginary vertical line -arrows- central‐
ly between camshaft sprockets.
• Lock three-stage sprocket with clamping pin -T10531/6-.
• Camshaft sprockets are locked in position at “TDC” with
clamp -T40271/1- and clamp -T40271/2-.
• Marking -arrow B- on exhaust camshaft must be offset half a

tooth in clockwise direction to marking -arrow A- on cylinder
head cover.
• The markings -arrows C- must align.
– Fit camshaft timing chain as shown onto camshaft journals
with coloured markings -arrows- properly aligned.
3. Chain drive 179

– Fit camshaft timing chain on inlet camshaft, exhaust cam‐

shaft and three-stage chain sprocket.
• Coloured chain links must align with markings on chain

sprockets -arrows-.
– Insert guide rail -2-, and tighten guide pins -1-.
– Allow upper guide rail -1- to engage in fastener -arrow-.

– Using assembly tool -T40427-, reduce preload of exhaust

camshaft in direction of -arrow B- and pull clamp -T40271/1-
out of teeth of chain sprocket -arrow C-.
– Have exhaust camshaft turned in direction of -arrow A- until
timing chain is in contact with guide rail -3-.
– Hold camshaft in this position, install tensioning rail -2- and
tighten guide pin -1-.
– Remove clamp -T40271/1-.
– Use assembly tool -T40427- to release pretension on inlet
camshaft in -direction of arrow A-, pull clamp -T40271/2-
out of sprocket teeth -arrow B-, and bring camshaft to rest
position.
– Remove clamp -T40271/2-.

– Screw in and tighten bolts -arrows-. Specified torque ⇒ Item
8 (page 141) .
3. Chain drive 181

– Lubricate holes -arrows- with engine oil.
– Check that clamping sleeve -1- is inserted.

– If bearing saddle is to be reused, clamping sleeve must be
driven back.
• Clamping sleeve must sit flush in housing of bearing saddle.
• Fit bearing saddle carefully. Keep straight.
– Fit bearing saddle and screw in bolts -1 to 6- as far as stop

by hand.
– Remove special tool -T40435-.
– Tighten bolts for bearing saddle ⇒ Fig. ““Bearing saddle
- specified torque and tightening sequence”“, page 170 .
When doing this, clamping sleeve is drawn into cylinder
head with bolt -2-.
– Check setting:


sprockets -arrows-.
– Install timing valves ⇒ Item 8 (page 169) .
– Fit drive chain for oil pump.
– Insert chain tensioner and tighten guide pins -2-.

– Attach retaining clip of tensioning spring -3- in recess on top
section of sump -arrow-.
3. Chain drive 183

NOTICE
– Install flange nut -T10531/4- and turning over tool -

T10531/3-.
NOTICE
Avoid damage to valves and piston crowns after working on
valve gear.
– Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
– Turn engine 2 revolutions in direction of engine rotation.

Please note:
The coloured chain links no longer align with the markings once
the engine has been turned.
– Unscrew flange nut and remove turning over tool.
– Install bearing saddle ⇒ a3.4 nd installing bearing saddle”,
page 196 .
– Renew lower timing chain cover ⇒ l2.2.2 ower timing chain
– Install upper timing chain cover ⇒ a2.2.1 nd installing upper
timing chain cover”, page 160 .
newing components of the chain drive ⇒ d3.2 iagnoses”, page
6.
Specified torques
♦ ⇒ o3.1 verview - camshaft timing chains”, page 168
♦ ⇒ o3.2 verview - drive chain for balance shaft”, page 170
3.3.2 Removing and installing camshaft tim‐

ing chain, DNNA, DNND

♦ Lever -T40243-
♦ Ratchet ring spanner, 21 mm -T40263-
♦ Camshaft clamp -T40271/3 und /4-
3. Chain drive 185

♦ Locking tool -T40435-
Removing
– Remove bearing saddle ⇒ a3.4 nd installing bearing saddle”,
page 196 .
NOTICE
– Using special wrench, WAF 21 -T40263- -item 6-, adapter -

T40314- -item 1- and suitable socket -arrow-, turn crankshaft
on vibration damper until camshafts are at “TDC”.

• Make sure that marking -3- of camshaft sprockets -2 and 5-

and marking -4- on cylinder head cover are aligned with
each other.
– Remove lower timing chain cover ⇒ l2.2.2 ower timing chain
– Check “TDC position” again.
– Detach retaining clip of tensioning spring -3- on top section
of sump -arrow-.
– Unscrew guide pin -2- and remove chain tensioner.

– Detach drive chain -1- for oil pump from three-stage
chain sprocket, and leave it suspended on clamping pin
-T10531/6-.
3. Chain drive 187


in that position.
Please note:
– Lock chain tensioner with locking tool -T40435-.

– Bolt camshaft clamp -T40271/3- to cylinder head.

– Insert camshaft clamp between teeth of chain sprocket

-arrow B-.
– If necessary, use adapter -T40427- to slightly turn inlet cam‐
shaft back and forth -arrows A-.
– Bolt camshaft clamp -T40271/4- to cylinder head.

– Hold exhaust camshaft with assembly tool -T40427-. Re‐
move guide pin -1- and remove tensioning rail -2- down‐
wards.
– Turn exhaust camshaft further clockwise -arrow A- until cam‐
shaft clamp -T40271/4- can be inserted into chain sprocket
splines -arrow B-.
– Unscrew bolts -arrows-, and remove guide rail -1-.
– Unscrew guide pins -1-, and remove guide rail -2-.
3. Chain drive 189

– Remove camshaft timing chain from camshaft sprockets,

NOTICE
Risk of irreparable damage to engine if valves strike piston
crowns.
– Do not turn crankshaft any further when camshaft timing
chain is removed.
Installing
Prerequisites:
• Lock three-stage chain sprocket with clamping pin -
T10531/6-.
• Camshaft sprockets are locked in position at “TDC” with
camshaft clamps -T40271/3- and -T40271/4-.

• Marking -arrow B- on exhaust camshaft must be offset half a

tooth in clockwise direction to marking -arrow A- on cylinder
head cover.
• The markings -arrows C- must align.
– Fit camshaft timing chain as shown onto camshaft journals
with coloured markings -arrows- properly aligned.
– Fit camshaft timing chain on inlet camshaft, exhaust cam‐

shaft and three-stage chain sprocket.
3. Chain drive 191


sprockets -arrows-.
– Insert guide rail -2-, and tighten guide pins -1-.
– Insert guide rail -1-, and tighten bolts -arrows-.

– Using assembly tool -T40427-, release pretension of ex‐

haust camshaft in direction of -arrow B-, and pull camshaft
clamp -T40271/4- out of chain sprocket splines -arrow C-.
– Have exhaust camshaft turned in direction of -arrow A- until
timing chain is in contact with guide rail -3-.
– Hold camshaft in this position, install tensioning rail -2- and
tighten guide pin -1-.
– Remove camshaft clamp -T40271/4-.
camshaft in -direction of arrow A-, pull camshaft clamp
-T40271/3- out of sprocket teeth -arrow 2-, and bring cam‐
shaft to rest position.
– Remove camshaft clamp -T40271/3-.

8 (page 141) .
3. Chain drive 193


driven back.

by hand.
– Remove locking tool -T40435-.
head with bolt -2-.
– Check setting:


sprockets -arrows-.
– Install timing valves ⇒ Item 8 (page 169) .
– Insert chain tensioner and tighten guide pins -2-.

– Attach retaining clip of tensioning spring -3- in recess on top
section of sump -arrow-.
3. Chain drive 195

NOTICE
– Fit flange nut -T10531/4- and turning tool -T10531/3-.
NOTICE
valve gear.
operated.
– Turn engine 2 revolutions in direction of engine rotation.

Please note:
Due to the ratio, the coloured chain links no longer align with
the markings after the engine has been turned.
– Unscrew flange nut and remove turning over tool.
– Renew lower timing chain cover ⇒ l2.2.2 ower timing chain
– Renew upper timing chain cover ⇒ a2.2.1 nd installing upper
6.
Specified torques
3.4 Removing and installing bearing sad‐

dle
♦ Assembly tool -T10352/2-

♦ Lever -T40243-
♦ Special tool -T40435-, not shown

Removing
– Remove timing chain cover (top) ⇒ a2.2.1 nd installing upper
• Observe direction of rotation: control valves have left-hand
thread - risk of thread damage.
3. Chain drive 197

– Remove left and right control valves with assembly tool -

T10352/2- -item 1- in clockwise direction -arrow-.
– Counterhold crankshaft on vibration damper with ratchet
ring spanner AF 21 -T40263-, adapter -T40314- and socket
AF 24.
• Pull off bearing saddle carefully. Keep straight.

– Remove bearing saddle.
Installing
– Remove sealing plug -arrow-.


– Unscrew bolt -arrow-.
• A second mechanic is required for the following work steps.

in that position.
Please note:
3. Chain drive 199

– Lock chain tensioner with special tool -T40435-.

8 (page 141) .

driven back.


by hand.
– Remove special tool -T40435-.
head with bolt -2-.
– Install upper timing chain cover ⇒ a2.2.1 nd installing upper
6.
Specified torques
♦ ⇒ Fig. ““Bearing saddle - specified torque and tightening
3.5 Checking timing chain

Procedure
insulation.
– Remove sealing plug -arrow-.

page 92 .
3. Chain drive 201

– Turn vibration damper in direction of engine rotation

until piston of chain tensioner is fully extended in
-direction of arrow-.
– Count piston notches that are visible.

Please note:
Visible notches are those located to the right from the chain
tensioner housing -top arrow-.
• If 6 or less notches are visible, the timing chain must not be
renewed.
• If 6 or fewer teeth are visible and there is an entry in the
event memory: adapt chain elongation ⇒ Vehicle diagnostic
tester, 0001 - Adaption chain elongation diagnosis
and erase event memory.
• If 7 or more teeth are visible: renew camshaft timing chain.
Specified torques
3.6 Removing and installing drive chain for

balance shaft
♦ Sealant for chain tensioner ⇒ Electronic parts catalogue
Removing
– Remove camshaft timing chain ⇒ a3.3 nd installing camshaft
timing chain”, page 173 .
Prerequisites:


– Unscrew bolts -4-, and remove tensioner for camshaft timing
chain.
– Unbolt chain tensioner -3- for drive chain of balance shaft.

– Unscrew guide pins -1 and 5-, and remove tensioning rail -2-
and guide rail -6-.
– Remove drive chain for balance shaft.
3. Chain drive 203

Installing

Prerequisites:
– Place drive chain for balance shaft as shown on balance
shaft for exhaust side and fit intermediate gear.
• Coloured chain links must align with markings -arrows- on

chain sprockets.
– Insert guide rail -1-, and tighten guide pins -arrows-.

– Align middle coloured chain link -arrow- of drive chain

for balance shaft with marking on three-stage sprocket as
– Insert tensioning rail -2-, and tighten guide pins -1-.

– Mount chain tensioner -arrow- with sealant ⇒ Electronic
parts catalogue and tighten.
– Check adjustment again:
3. Chain drive 205

• Middle coloured chain link must be opposite marking

-arrow A- on three-stage chain sprocket.
• Coloured chain links must be opposite markings -arrows B-
on balance shaft for exhaust side and intermediate gear.
– Install camshaft timing chain ⇒ a3.3 nd installing camshaft
Specified torques

4 Valve gear
⇒ o4.1 verview – valve gear”, page 207
⇒ a4.2 nd installing camshaft”, page 215
⇒ a4.3 nd installing actuators for camshaft adjustment”, page
233
⇒ a4.4 nd installing camshaft control valves N205/N318”, page
234
⇒ a4.5 nd installing valve stem seals”, page 235
4.1 Assembly overview – valve gear

⇒ o4.1.1 verview – valve gear, DNPA, DNFC, DNFE, DNFG,
DSFE, DRNA, DSFB, DSFF”, page 207
⇒ o4.1.2 verview – valve gear, DNNA, DNND”, page 211
4.1.1 Assembly overview – valve gear, DNPA, DNFC, DNFE, DNFG, DSFE,
DRNA, DSFB, DSFF
4. Valve gear 207

1 - Outlet valve
❑ Do not rework. Only
lapping in is permitted.
❑ Valve dimensions ⇒
d5.3 imensions”, page
248
❑ Checking valve guides
⇒ v5.1 alve guides”,
page 247
2 - Inlet valve
248
page 247
3 - Cylinder head
o1.1 verview - cylinder
head”, page 140
4 - Valve stem seal
❑ Allocation ⇒ Fig. ““Allo‐
cation of valve stem oil
seals”“, page 241
❑ Renewing ⇒ a4.5 nd
installing valve stem
seals”, page 235
5 - Valve springs
❑ Installation position and
allocation ⇒ Fig. ““In‐
stallation position and
allocation of valve
springs”“, page 210
6 - Valve spring plate
7 - Valve cotters
8 - Hydraulic compensation element
❑ Do not interchange
❑ Apply engine oil to contact surface
9 - Roller rocker fingers
❑ Removing and installing ⇒ a4.2 nd installing camshaft”, page 215
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Installation position and allocation ⇒ Fig. ““Allocation of roller rocker fingers”“, page 210
10 - Retaining clip
❑ For hydraulic compensation element.
11 - Exhaust camshaft
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Axial clearance: new 0.1 +0.102–0.05 mm

❑ Radial clearance: 0.024 to 0.066 mm.
❑ Maximum run-out: 0.04 mm
12 - Spring
13 - Ball
❑ For sliding piece
❑ Installing ⇒ page 224
❑ With integrated camshaft bearings.
❑ Sealing surface should only be cleaned; reworking not permitted
❑ Remove sealant residue.
❑ Observe pair number of cylinder head cover and cylinder head ⇒ Fig. ““Pair number of cylinder head
cover and cylinder head”“, page 143
15 - Bolt
❑ Specified torques and tightening sequence ⇒ Fig. ““Cylinder head cover - specified torque and tighten‐
ing sequence”“, page 210
16 - O-ring
17 - Bolt
❑ 4.5 Nm
18 - Actuator for camshaft adjustment
♦ Actuator 1 for camshaft adjustment -F366-
❑ Removing and installing ⇒ a4.3 nd installing actuators for camshaft adjustment”, page 233
19 - Ball stud
❑ For engine cover panel
❑ Qty. 2
❑ 9 Nm
20 - Bracket
❑ For wiring harness
21 - Bolt
❑ 9 Nm
22 - Plug
23 - O-ring
24 - Inlet camshaft
4. Valve gear 209

25 - Dowel pin
❑ Qty. 2
Cylinder head cover - specified torque and tightening sequence

after each removal.
• Take care to keep cylinder head cover level.
1 Screw in by hand in several stages as far as stop
2 8 Nm
3 Turn 90° further
Installation position and allocation of valve springs
• The closely spaced spring coils -arrow- face the cylinder

head.
• Length of valve spring on inlet side approx. 45.5 mm.
• Length of valve spring on exhaust side approx. 51.0 mm.
Allocation of roller rocker fingers

• Roller rocker fingers inlet side: dimension -a- = 5.4 mm

• Roller rocker fingers exhaust side: dimension -a- = 8.0 mm
4.1.2 Assembly overview – valve gear, DNNA, DNND
4. Valve gear 211

1 - Outlet valve
248
page 247
2 - Cylinder head
❑ Cylinder head and
cylinder head cover
should always be re‐
newed together
3 - Not installed
4 - Valve stem seal
❑ Different versions ⇒
Fig. ““Allocation of
valve stem oil seals”“,
page 241
❑ Renewing ⇒ a4.5 nd
installing valve stem
seals”, page 235
5 - Valve springs
❑ Installation position and
allocation ⇒ page 214
6 - Hydraulic compensation
element
❑ Do not interchange
❑ Apply engine oil to con‐
tact surface
7 - Upper valve spring plate
8 - Valve cotters
9 - Retaining clip
❑ For hydraulic compensation element.
10 - Roller rocker fingers
❑ Mark installation position for re-installation.
❑ Allocation ⇒ page 214 .
❑ Check roller bearing for ease of movement.
11 - Exhaust camshaft
❑ With integrated camshaft bearings.

❑ Sealing surface should only be cleaned; reworking not permitted
❑ Remove sealant residue.
❑ Cylinder head and cylinder head cover should always be renewed together
13 - Bolt
❑ Specified torques and tightening sequence ⇒ page 214
14 - Ball stud
❑ 9 Nm
15 - Bracket
❑ For wiring harness
16 - Bolt
❑ 9 Nm
17 - Plug
18 - O-ring
19 - O-ring
❑ Not a replacement part; provided together with actuator for camshaft adjustment
20 - Actuator for camshaft adjustment
❑ Removing and installing ⇒ a4.3 nd installing actuators for camshaft adjustment”, page 233
❑ Bring into installation position ⇒ page 234
21 - Bolt
❑ 4.5 Nm
22 - Spring
23 - Ball
❑ For sliding piece
24 - Inlet camshaft
❑ Runout: max. 0.04 mm
25 - Dowel pin
❑ Qty. 2
4. Valve gear 213

26 - Inlet valve
❑ Do not rework. Only lapping in is permitted.
❑ Valve dimensions ⇒ d5.3 imensions”, page 248
❑ Checking valve guides ⇒ v5.1 alve guides”, page 247
Cylinder head cover - specified torque and tightening sequence

after each removal.
1 Screw in by hand in several stages as far as stop
2 8 Nm
3 Turn 90° further
Installation position and allocation of valve springs
• The closely spaced spring coils -arrow- face the cylinder

head.
• Length of valve spring on inlet side approx. 45.5 mm.
• Length of valve spring on exhaust side approx. 51.0 mm.
Allocation of roller rocker fingers

• Roller rocker fingers inlet side: dimension -a- = 5.4 mm

• Roller rocker fingers exhaust side: dimension -a- = 8.0 mm
4.2 Removing and installing camshaft

⇒ a4.2.1 nd installing camshaft, DNPA, DNFC, DNFE, DNFG,
DSFE, DRNA, DSFB, DSFF”, page 215
⇒ a4.2.2 nd installing camshaft, DNNA, DNND”, page 225
4.2.1 Removing and installing camshaft,

DNPA, DNFC, DNFE, DNFG, DSFE,
DRNA, DSFB, DSFF
Removing
– Briefly open filler cap -arrow- for coolant expansion tank in
order to reduce residual pressure in cooling system.
– Remove left air intake pipe ⇒ a2.6.3 nd installing air intake

pipe between turbocharger and charge air cooler”, page
371 .
page 494 .
– Remove upper coolant pipe ⇒ a3.2.2 nd installing upper
coolant pipe”, page 311 .
– Disconnect connector -2- for sender 1 for turbocharger
speed -G688-.
4. Valve gear 215

1- For activated charcoal filter system solenoid valve 1 -N80-

2- For pressure differential sender for particulate filter -
G1037-
3- For Hall sender 2 -G163-
4- For for fuel pressure regulating valve -N276-/fuel metering
valve -N290-
– Unplug electrical connectors -arrows- at actuators for cam‐
shaft adjustment.
– Free off wiring harness and swivel it forwards.
NOTICE
Risk of damage to coolant pipes caused by deformation.
– Never attempt to reshape the coolant pipe.

– Unscrew bolts -arrows- and carefully swivel coolant bleeder

line to one side.
– Remove vacuum pump ⇒ a1.3 nd installing vacuum pump”,
page 153 .
– Bring engine support and engine mounting into installation
position and tighten bolts to 20 Nm.
– Detach support bracket from engine.
– Press release tabs on crankcase breather hose -1- on both

sides and remove Venturi nozzle.
– Remove oil separator ⇒ a3.2 nd installing oil separator”,
page 264 .
– Fit turning over tool -T10531/3-. At “TDC position” the flat
section -1- faces upwards. Screw on flange nut -T10531/4-.
Turn crankshaft with a 32 mm open-end spanner 90° anti-
clockwise out of “TDC position”.

camshaft in direction of -arrow B-, pull clamp -T40271/2- out
of sprocket teeth -arrow A-, and bring inlet camshaft to rest
position.
4. Valve gear 217

– Use assembly tool -T40427- to release pretension on

exhaust camshaft in direction of -arrow B-, pull clamp -
T40271/1- out of sprocket teeth -arrow A- and bring exhaust
camshaft to rest position.
– Unscrew cylinder head cover bolts in the sequence -1 … 6-.
– Carefully detach cylinder head cover -2- from adhesive bond

using a screwdriver -1- and remove together with camshafts.

• Make sure when doing this that camshafts do not fall out of
cylinder head cover.
– Remove camshafts, and cover open parts of engine.
– If necessary for further steps: mark roller rocker fingers
and hydraulic compensation elements for later installation,
remove and place on a clean surface.
Installing
• Crankshaft must not be at “TDC” position.
after each removal.
– If removed, install roller rocker fingers and hydraulic com‐
pensation elements according to drawing ⇒ Fig. ““Allocation
of roller rocker fingers”“, page 210 .
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensa‐
tion elements.
If crankshaft has been turned in the meantime:
4. Valve gear 219

– Turn crankshaft via hex -2- to “TDC position”.

• In “TDC position”, flat -1- is in an imaginary vertical line
between camshaft sprockets.
– Then turn crankshaft 90° in anti-clockwise direction out of
“TDC position”.
– Cover any exposed parts with a clean cloth.
CAUTION
– Remove sealant residue on cylinder head with a flat scraper

(at least 40 mm wide).
– Remove sealant residue from groove in cylinder head cover
and from sealing surfaces.
– Bring pins of actuators for camshaft adjustment into installa‐
tion position ⇒ page 234 .
– Oil contact surfaces of camshafts with engine oil.
– Pull off clamps -T40271/1- and -T40271/2- from cylinder
head -arrows-.
– Insert inlet camshaft -1- in cylinder head and align to mark‐

ing -2-.
• Angle α = 30°
• Turn cams for cylinder 4 upwards.
– Align inlet camshaft centrally to roller rocker fingers.

CAUTION
The ball for the sliding piece may pop out! Risk of eye injury!
– Insert exhaust camshaft into cylinder head cover.

• Push cam pairs -A- and -B- towards each other.
– Turn exhaust camshaft until markings -A- and -B- are prop‐
erly aligned.
4. Valve gear 221

NOTICE
system.
– Apply sealant to clean sealing surface of cylinder head cover

as shown in illustration -arrows-.
• Thickness of sealant bead: 1.5 to 2.5 mm.
– Hold camshaft and fit cylinder head cover with camshaft on
cylinder head, paying attention to dowel pins.
– Press cylinder head cover lightly with one hand and turn
camshafts back and forth -arrows- slightly until cylinder head
cover is properly seated on cylinder head »free of stress«.
– Tighten bolts in several stages ⇒ Fig. ““Cylinder head cover -

specified torque and tightening sequence”“, page 210 .
• When tightening, remove any sealant residue that may es‐
cape.
– Turn inlet camshaft in direction of -arrow B- using assembly
tool -T40427- until markings -1- and -2- align.

– Insert clamp -T40271/2- in teeth of chain sprocket -arrow A-.

– Turn exhaust camshaft in direction of -arrow B- with assem‐
bly tool -T40427- until marking -2- of exhaust camshaft is
offset to marking -1- on cylinder head cover by half a tooth in
clockwise direction.
– Insert clamp -T40271/1- in teeth of chain sprocket -arrow A-.

– Turn crankshaft on hexagon to “TDC position”.
• Flat -1- must point upwards.

– Remove flange nut -T10531/4- and turning over tool -
T10531/3-.
4. Valve gear 223

– Install oil separator ⇒ a3.2 nd installing oil separator”, page

264 .
– Install vacuum pump ⇒ a1.3 nd installing vacuum pump”,
page 153 .
– Install upper coolant pipe ⇒ a3.2.2 nd installing upper cool‐
494 .
– Install left air intake pipe ⇒ a2.6.3 nd installing air intake pipe
between turbocharger and charge air cooler”, page 371 .
NOTICE
valve gear.
– Do not start engine until at least 30 minutes after installing
camshaft as hydraulic compensation elements need time
to settle.
operated.

newing the camshafts ⇒ d3.2 iagnoses”, page 6 .
Specified torques
♦ ⇒ o4.1 verview – valve gear”, page 207
Installing ball for sliding piece
♦ Spacer -T40191/1-

Installing
CAUTION
– Insert spring -1- into camshaft.

– Place ball -2- onto spring in camshaft.
– Using spacer -T40191/1-, press down ball and spring
(-arrow A-) and hold in this position.
– Slide sliding piece -3- in -direction of arrow B-.
4.2.2 Removing and installing camshaft,

DNNA, DNND
Removing
– Briefly open filler cap -arrow- for coolant expansion tank in
order to reduce residual pressure in cooling system.

371 .
page 494 .
4. Valve gear 225



G1037-
3- For turbocharger air recirculation valve -N249-.
valve -N290-
shaft adjustment.
NOTICE

line to one side.
– Remove vacuum pump ⇒ a1.3 nd installing vacuum pump”,
page 153 .

– Bring engine support and engine mounting into installation

position and tighten bolts to 20 Nm.
– Detach support bracket from engine.

sides and remove Venturi nozzle (example figure).
– Remove oil separator ⇒ a3.2 nd installing oil separator”,
page 264 .
– Fit turning over tool -T10531/3-. At “TDC position” the flat
section -1- faces upwards. Screw on flange nut -T10531/4-.
Turn crankshaft with a 32 mm open-end spanner 90° anti-
clockwise out of “TDC position”.

camshaft in direction of -arrow B-, pull camshaft clamp -
T40271/3- out of sprocket teeth -arrow A-, and bring inlet
– Use assembly tool -T40427- to release pretension on ex‐

haust camshaft in direction of -arrow B-, pull camshaft clamp
4. Valve gear 227

-T40271/4- out of sprocket teeth -arrow A- and bring exhaust

– Unscrew cylinder head cover bolts in the sequence -1 … 6-.
– Carefully detach cylinder head cover -2- from adhesive bond

using a screwdriver -1- and remove together with camshafts.
• Make sure when doing this that camshafts do not fall out of
cylinder head cover.
– Remove camshafts, and cover open parts of engine.
– If necessary for further steps: mark roller rocker fingers
and hydraulic compensation elements for later installation,
remove and place on a clean surface.

Installing
• Crankshaft must not be at “TDC” position.
after each removal.
• Check O-ring in crankcase pressure sensor -G1068- for
damage ⇒ o3.1 verview - crankcase breather system”, page
263 .
– If removed, install roller rocker fingers and hydraulic com‐
pensation elements according to drawing ⇒ Fig. ““Allocation
of roller rocker fingers”“, page 210 .
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensa‐
tion elements.
If crankshaft has been turned in the meantime:
– Turn crankshaft via hex -2- to “TDC position”.

• In “TDC position”, flat -1- is in an imaginary vertical line
between camshaft sprockets.
– Then turn crankshaft 90° in anti-clockwise direction out of
“TDC position”.
– Cover any exposed parts with a clean cloth.
CAUTION
– Remove sealant residue on cylinder head with a flat scraper

(at least 40 mm wide).
– Remove sealant residue from groove in cylinder head cover
and from sealing surfaces.
– Bring pins of actuators for camshaft adjustment into installa‐
tion position ⇒ page 234 .
– Oil contact surfaces of camshafts with engine oil.
– Align exhaust camshaft centrally to roller rocker fingers.
4. Valve gear 229

– Insert exhaust camshaft in cylinder head and turn cams

-arrows- from cylinder 4 upwards.
CAUTION
– Insert inlet camshaft into cylinder head cover.

• Push cam pairs -A- and -B- towards each other.
– Turn exhaust camshaft until markings -A- and -B- are prop‐
erly aligned.

NOTICE
system.
– Apply sealant to clean sealing surface of cylinder head cover

as shown in illustration -arrows-.
• Thickness of sealant bead: 1.5 to 2.5 mm.
– Hold camshaft and fit cylinder head cover with camshaft on
cylinder head, paying attention to dowel pins.
– Press cylinder head cover lightly with one hand and turn
camshafts back and forth -arrows- slightly until cylinder head
cover is properly seated on cylinder head »free of stress«.
– Tighten bolts in several stages ⇒ Fig. ““Cylinder head cover -

specified torque and tightening sequence”“, page 210 .
– Turn inlet camshaft in direction of -arrow B- using assembly
tool -T40427- until markings -1- and -2- align.
4. Valve gear 231

– Insert camshaft clamp -T40271/3- in teeth of chain sprocket

-arrow A-.
– Turn exhaust camshaft in direction of -arrow B- with assem‐
bly tool -T40427- until marking -2- of exhaust camshaft is
offset to marking -1- on cylinder head cover by half a tooth in
clockwise direction.
– Insert camshaft clamp -T40271/4- in teeth of chain sprocket

-arrow A-.
– Turn crankshaft on hexagon to “TDC position”.
• Flat -1- must point upwards.

– Remove flange nut -T10531/4- and turning tool -T10531/3-.


– Install oil separator ⇒ a3.2 nd installing oil separator”, page
264 .
– Install vacuum pump ⇒ a1.3 nd installing vacuum pump”,
page 153 .
494 .
NOTICE
valve gear.
to settle.
operated.

newing the camshafts ⇒ d3.2 iagnoses”, page 6 .
Specified torques
♦ ⇒ a4.2 nd installing camshaft”, page 215
4.3 Removing and installing actuators for

camshaft adjustment
Removing
er”, page 76 .
– Free off wires of cam adjustment actuator 1 -F366- and push
aside slightly.
– Disconnect relevant electrical connector -2-.
4. Valve gear 233

– Unscrew bolt -1-, and pull off actuator for camshaft adjust‐
ment.
Installing

• Renew O-rings if damaged or leaking.
• Pin of variable valve timing actuator must be brought into
installation position.
– Press down pin of cam adjustment actuator -arrow- by hand.
• Actuator pin must not be in extended position.
– Moisten O-rings with engine oil.
page 76 .
Specified torques
4.4 Removing and installing camshaft con‐

trol valves -N205-/-N318-
Removing
er”, page 76 .
1 - For exhaust camshaft control valve 1 -N318-.

3 - For camshaft control valve 1 -N205-
– Unscrew bolts -arrows- and remove camshaft control valve.
2 - Exhaust camshaft control valve 1 -N318-
4 - Inlet camshaft control valve 1 -N205-

Installing
• Check seals for damage and leaks. Renew seals, if neces‐
sary, by removing upper timing chain cover ⇒ Item 13 (page
158) .
• Renew O-rings and bolts after removal.
– Lubricate sealing surface of O-rings for camshaft control
valve with engine oil.
page 76 .
Specified torques
4.5 Removing and installing valve stem

seals
⇒ a4.5.1 nd installing valve stem seals (cylinder head instal‐
led)”, page 235
⇒ a4.5.2 nd installing valve stem seals (cylinder head re‐
moved)”, page 241
4.5.1 Removing and installing valve stem

seals (cylinder head installed)
♦ Puller -3364-
4. Valve gear 235

♦ Valve stem oil seal fitting tool -3365- with single sealing lip ⇒
Fig. ““Allocation of valve stem oil seals”“, page 241
♦ Valve stem oil seal fitting tool -T40376/1- with double sealing
lip ⇒ Fig. ““Allocation of valve stem oil seals”“, page 241
♦ Removal and installation device for valve cotters -VAS

5161A- with guide plate for FSI engine -VAS 5161/19C-
♦ Assembly sleeve ⇒ Electronic parts catalogue

Removing
– Remove camshafts ⇒ page 215 .
– Cylinder 1 inlet side: unscrew bolts -arrows- and remove
engine lifting eye -1-.

– Unscrew spark plugs using spark plug socket and extension

-3122B-.
– Set piston of respective cylinder to “bottom dead centre”,

turning crankshaft at hexagon of turning over tool T10531/3
to do so.
– Check if recess -arrow- is present.
4. Valve gear 237

– If necessary, rework guide plate for FSI engine -VAS

5161/19C- -arrow- until it rests against cylinder head and
guide pin -1- is free.
– Align guide plate on cylinder head, taking account of mark‐
ings when doing so:
A - Exhaust valves
E - Inlet valves
– Secure guide plate for FSI engine -VAS 5161/19C- using
knurled screws -VAS 5161/12-.
– Insert drift -VAS 5161/3A- into valve spring plate and use
a plastic hammer to knock loose the firmly seated valve
cotters.
– Screw adapter -T40012- into spark plug thread.
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
• Minimum pressure: 6 bar.
– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.
– Push assembly cartridge into guide plate -VAS 5161/8A-.

– Attach pressure fork -VAS 5161/2- to toothed piece and
press assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve
cotters and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and move to side.

• The compressed air hose remains connected.

– Remove valve spring and valve spring plate.
– Pull off valve stem oil seal using puller -3364-.
Installing
• To prevent damage to new valve stem oil seal -4- during

installation, fit assembly sleeve -3- on valve stem -2-.
– Lightly oil sealing lip of valve stem seal.
• Depending on version/manufacturer of valve stem oil seal,
use press tool -3365- or press tool -T40376/1-.
– Insert valve stem oil seal in fitting tool -5- and carefully push
onto valve guide -1- via assembly sleeve as far as stop.
– Remove assembly sleeve.
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device
-VAS 5161/18-.
4. Valve gear 239

• Larger diameter of valve cotters faces upwards.

– Press assembly cartridge onto valve insertion device from
above, and pick up valve cotters.
– Insert valve spring and valve spring plate. Note installation
position and allocation ⇒ page 207 .
– Mount guide plate for FSI engine -VAS 5161/19C- again on
cylinder head.
– Insert assembly cartridge into guide plate.

– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts
the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Installing
Assembly is carried out in reverse sequence; note the following:
– Install camshafts ⇒ a4.2 nd installing camshaft”, page 215 .
492 .
NOTICE
valve gear.
to settle.
operated.

Specified torques
Allocation of valve stem oil seals
A - Valve stem oil seal with sealing lip -A-, coloured green
♦ For inlet side
B - Valve stem oil seal with two sealing lips -A-, coloured red
♦ For exhaust side
4.5.2 Removing and installing valve stem

seals (cylinder head removed)
♦ Puller -3364-
4. Valve gear 241

♦ Valve stem oil seal fitting tool -3365- with single sealing lip ⇒
Fig. ““Allocation of valve stem oil seals”“, page 241
♦ Valve stem oil seal fitting tool -T40376/1- with double sealing
lip ⇒ Fig. ““Allocation of valve stem oil seals”“, page 241
♦ Removal and installation device for valve cotters -VAS

5161A- with guide plate for FSI engine -VAS 5161/19C-
♦ Engine and gearbox support -VAS 6095-

♦ Cylinder head tensioning device -VAS 6419-
♦ Assembly sleeve ⇒ Electronic parts catalogue

Removing
– Remove intake manifold ⇒ a5.2 nd installing intake mani‐
fold”, page 406 .
– If required, remove turbocharger ⇒ a1.2 nd installing turbo‐
charger”, page 347 .
– Insert cylinder head tensioning device -VAS 6419- into en‐
gine and gearbox support -VAS 6095-.
– Tension cylinder head on cylinder head tensioning device as

– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion
chamber from which valve stem oil seal is to be removed.
– Allow compressed air to flow into air cushion until it lies
against valve disc.
– Check if recess -arrow- is present.
4. Valve gear 243

– If necessary, rework guide plate for FSI engine -VAS

5161/19C- -arrow- until it rests against cylinder head and
guide pin -1- is free.
– Align guide plate on cylinder head, taking account of mark‐
ings when doing so:
A - Exhaust valves
E - Inlet valves
– Secure guide plate for FSI engine -VAS 5161/19C- using
knurled screws -VAS 5161/12-.
– Insert drift -VAS 5161/3A- into valve spring plate and use
a plastic hammer to knock loose the firmly seated valve
cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -
VAS 5161/5- into guide plate.
– Push assembly cartridge into guide plate -VAS 5161/8A-.

– Attach pressure fork -VAS 5161/2- to toothed piece and
press assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve
cotters and capture them in assembly cartridge.
– Release pressure fork.
– Remove installation cartridge.
– Unbolt guide plate and remove.
– Remove valve spring and valve spring plate.
– Pull off valve stem oil seal using puller -3364-.

Installing
• To prevent damage to new valve stem oil seal -4- during

installation, fit assembly sleeve -3- on valve stem -2-.
– Lightly oil sealing lip of valve stem seal.
• Depending on version of valve stem oil seal, use press tool
-3365- or press tool -T40376/1-.
– Insert valve stem oil seal in fitting tool -5- and carefully push
onto valve guide -1- via assembly sleeve as far as stop.
– Remove assembly sleeve.
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device
-VAS 5161/18-.
4. Valve gear 245

• Larger diameter of valve cotters faces upwards.

– Press assembly cartridge onto valve insertion device from
above, and pick up valve cotters.
– Insert valve spring and valve spring plate. Note installation
position and allocation ⇒ page 207 .
– Mount guide plate for FSI engine -VAS 5161/19C- again on
cylinder head.
– Insert assembly cartridge into guide plate.

– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts
the valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Installing
– If removed, install turbocharger ⇒ a1.2 nd installing turbo‐
charger”, page 347 .
– Install intake manifold ⇒ a5.2 nd installing intake manifold”,
page 406 .

5 Inlet and exhaust valves

⇒ v5.1 alve guides”, page 247
⇒ v5.2 alves”, page 248
⇒ d5.3 imensions”, page 248
5.1 Checking valve guides

♦ Universal dial gauge holder -VW387-
♦ Dial gauge -VAS 6079-
Test sequence
• If the valve is to be renewed as part of a repair, use a new

valve for the calculation.
• Only insert inlet valve into inlet valve guide and exhaust
valve into exhaust valve guide, as the stem diameters are
different.
– Insert valve into valve guide.
• End of valve stem must be flush with valve guide.
5. Inlet and exhaust valves 247

– Determine rock.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Please note:
Valve guides cannot be exchanged.
5.2 Checking valves

– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.
5.3 Valve dimensions
• Never rework the inlet and exhaust valves. Only lapping-in is

permitted.
Dimension Inlet valve Outlet valve
∅a mm 33.85 ± 0.10 28.0 ± 0.1
b mm 103.97 101.87
Diameter mm 5.92 ± 0.02 5.92 ± 0.02
c
d ∠° 45 45

17 – Lubrication
1 Sump, oil pump
⇒ o1.1 verview - sump/oil pump”, page 249
⇒ o1.2 il:”, page 252
⇒ a1.3 nd installing lower part of sump”, page 252
⇒ a1.4 nd installing oil pump”, page 253
⇒ a1.5 nd installing upper part of sump”, page 254
⇒ a1.6 nd installing oil level and oil temperature senderG266”,
page 259
1.1 Assembly overview - sump/oil pump

If large amounts of metal filings or swarf is found in the engine
oil when engine repairs are carried out, the oil ducts must be
carefully cleaned in order to prevent subsequent damage. Re‐
new additional oil spray jets, engine oil cooler and oil filter.
1. Sump, oil pump 249

1 - Suction line
❑ Clean strainer if soiled
2 - Bolt
❑ 4 Nm +45°
3 - O-ring
4 - Bolt
❑ 8 Nm +90°
5 - Oil pump
oil pump”, page 253
6 - Dowel sleeve
❑ Qty. 2
❑ For oil pump.
7 - Oil strainer
8 - O-ring
9 - Bolt
❑ ⇒ Item 2 (page 268)
10 - Valve for oil pressure
control -N428-
❑ ⇒ Item 3 (page 268)
11 - Drive chain for oil pump
❑ Mark direction of rotation before removing.
12 - Guide pin
❑ 9 Nm
13 - Chain tensioner
14 - Cylinder block
15 - Upper part of sump
❑ Removing and installing ⇒ a1.5 nd installing upper part of sump”, page 254
16 - Bolt
❑ Tightening sequence ⇒ Fig. ““Top section of sump - specified torques and tightening sequence”“, page
251
17 - Plug
18 - Lower part of sump
❑ Removing and installing ⇒ a1.3 nd installing lower part of sump”, page 252
19 - Seal
20 - Nut
❑ 9 Nm
21 - Oil level and oil temperature sender -G266-
250 Rep. gr.17 - Lubrication

❑ Removing and installing ⇒ a1.6 nd installing oil level and oil temperature senderG266”, page 259
22 - Seal
23 - Oil drain plug
❑ 30 Nm
24 - Bolt
❑ Tightening sequence ⇒ Fig. ““Bottom section of sump - specified torques and tightening sequence”“,
page 251
Bottom section of sump - specified torques and tightening se‐

quence

after each removal.
2 8 Nm
3 Turn 45° further
Top section of sump - specified torques and tightening se‐
quence

after each removal.
tions
1 -1 to 18- 8 Nm


tions
2 -1, 2- Turn 180° further
1.2 Engine oil:

Capacities and specifications ⇒ Maintenance; Booklet ; Engine
oil: Capacities and specifications.
Change engine oil ⇒ Maintenance; Booklet ; Engine oil: Drain‐
ing; Renewing oil filter and replenishing engine oil.
Check engine oil level ⇒ Maintenance; Booklet ; Engine oil lev‐
el: Checking.
1.3 Removing and installing lower part of

sump
Removing
insulation.
– Drain engine oil ⇒ o1.2 il:”, page 252 .
– Disconnect electrical connector -1- for oil level and oil tem‐
perature sender -G266-.
– Unscrew bolts -1 to 20- and carefully detach bottom section

of sump from adhesive bond.
– If bottom section of sump is renewed, remove oil level and

oil temperature sender -G266- ⇒ page 259 .

Installing
• Renew seal and O-ring after removal.
– Replenishing engine oil ⇒ o1.2 il:”, page 252 .
Specified torques
♦ ⇒ Fig. ““Bottom section of sump - specified torques and
1.4 Removing and installing oil pump

♦ Locating pins -T40414-
Removing
– Remove sump (bottom section) ⇒ a1.3 nd installing lower
part of sump”, page 252 .
– Place locating pins -T40414- on chain tensioner -1-, press
in direction of -arrow- and secure by tightening bolt -2- to
9 Nm.
– Unscrew bolts -arrows- for oil pump -2-.

– Detach drive chain -1- and remove oil pump.

Installing
– Check that both dowel sleeves for centring are inserted in oil
pump.
– Before installing, check strainer ⇒ Item 7 (page 250) in oil
pump and oil galleries in upper part of sump for soiling.
– Guide oil pump chain sprocket into drive chain and install oil
pump.
– Remove locating pins -T40414- and check to ensure that
drive chain is fitted correctly on chain sprocket.
– Install bottom section of sump ⇒ a1.3 nd installing lower part
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 249
♦ ⇒ o2.1 verview – charge air system”, page 357
1.5 Removing and installing upper part of

sump

♦ Bit -T10573-
♦ Hand drill with plastic brush

♦ Safety goggles
Removing
– Remove sealing flange on gearbox side ⇒ a2.3 nd installing
sealing flange on gearbox side”, page 99 .
– Remove oil pump -2- ⇒ a1.4 nd installing oil pump”, page
253 .
– Unscrew front air pipe but leave in installation position ⇒

a2.6.1 nd installing air intake pipe for throttle valve mod‐
ule/charge air cooler, DNFC, DNFE, DNFG, DSFB, DSFE,
DSFF”, page 368 .
– Remove locating pins -T40414- and bring tensioning rail for
drive chain -1- into rest position.
– Separate electrical connector -1- for valve for oil pressure
control -N428-.

– Pull off plug from bolt -14-.
– Unscrew bolts -1 to 18- and detach top section of sump from

bonded joint.
• Lever off upper part of sump on gearbox side first. When
levering off, proceed with caution to avoid damaging the
timing chain cover.
Installing
after each removal.
– Remove sealant residues from cylinder block with a flat scra‐
per.

CAUTION
– Remove remaining sealant on top section of sump -1- and

lower timing chain cover e.g. using rotating plastic brush.
• Check timing chain cover for deformation. To do this, fit
sump upper part first without sealant and check gap be‐
tween cover and sump upper part. If deformation is evident
and cover cannot be aligned, renew cover after top section
of sump has been installed.
– Check oil galleries in upper part of sump and cylinder block
for soiling.

2 mm).

NOTICE
Danger of blocking lubrication system with excess sealant.
♦ Thickness of sealant bead: 2 to 3 mm.

– Apply sealant to clean sealing surface of sump top section
-arrows- as shown in illustration.
– Apply sealant between cylinder block and lower timing chain
cover -arrows-.
• The upper part of the sump must be installed within 5 mi‐

nutes after applying sealant.
• Top section of sump and cylinder block must be flush on
gearbox side.
– Install top section of sump immediately, guiding drive chain
for oil pump when doing so.
– Tighten bolts.

– Attach retaining clip -1- of chain tensioner spring using as‐

sembly tool -T10118- at cast-on part -arrow- of sump top
section.

– Install sealing flange on gearbox end ⇒ a2.3 nd installing
sealing flange on gearbox side”, page 99 .
– Install oil pump ⇒ a1.4 nd installing oil pump”, page 253 .
Specified torques
♦ ⇒ Fig. ““Top section of sump - specified torques and tighten‐
♦ ⇒ Item 17 (page 159)
1.6 Removing and installing oil level and

oil temperature sender -G266-
Removing
• Engine oil drained ⇒ o1.2 il:”, page 252
– Unscrew nuts -1-, remove oil level and oil temperature send‐
er -G266- -item 3-.
Installing

• Renew seal -4- after each removal.

– Replenishing engine oil ⇒ o1.2 il:”, page 252 .
Specified torques
♦ ⇒ o1.1 verview - sump/oil pump”, page 249

2 Engine oil cooler

⇒ o2.1 verview - engine oil cooler”, page 261
⇒ a2.2 nd installing engine oil cooler”, page 261
2.1 Assembly overview - engine oil cooler
bracket for ancillaries”,
page 89
2 - Seal
3 - O-ring
4 - Mechanical switching
valve
ling ⇒ a2.2.2 nd instal‐
ling mechanical switch‐
ing valve”, page 262
5 - Engine oil cooler
❑ Observe notes ⇒ page
249
ling engine oil cooler”,
page 261
6 - Bolt
❑ 8 Nm +45°
2.2 Removing and installing engine oil

cooler
⇒ a2.2.1 nd installing engine oil cooler”, page 261
⇒ a2.2.2 nd installing mechanical switching valve”, page 262
2.2.1 Removing and installing engine oil

cooler
Removing
– Remove bracket for ancillaries ⇒ a1.5 nd installing bracket
for ancillaries”, page 89 .
– Unscrew bolts -4, 5- and remove engine oil cooler -3- with
seal -2- from ancillaries bracket -1-.
2. Engine oil cooler 261

Installing
– Install bracket for ancillaries ⇒ a1.5 nd installing bracket for
ancillaries”, page 89 .
Specified torques
♦ ⇒ o2.1 verview - engine oil cooler”, page 261
2.2.2 Removing and installing mechanical

switching valve
Removing
– Remove engine oil cooler ⇒ a2.2.1 nd installing engine oil
cooler”, page 261 .
– Remove mechanical switching valve -1- from ancillary brack‐
et -arrow-.
Installing
– Moisten O-rings of mechanical switching valve with engine
oil, and install switching valve.
– Install engine oil cooler ⇒ a2.2.1 nd installing engine oil cool‐
er”, page 261 .

3 Crankcase ventilation
⇒ o3.1 verview - crankcase breather system”, page 263
⇒ a3.2 nd installing oil separator”, page 264
⇒ a3.3 nd installing crankcase pressure sensorG1068”, page
265
3.1 Assembly overview - crankcase breather system

2 - Hose
❑ To activated charcoal
filter solenoid valve 1 -
N80-
3 - O-ring
❑ Renew if damaged or
leaking
4 - Hose
❑ For crankcase ventila‐
tion.
❑ To turbocharger
❑ Different versions; for
allocation refer to
logue
5 - Crankcase pressure sen‐
sor -G1068-
❑ Equipment version
ling ⇒ a3.3 nd instal‐
ling crankcase pressure
sensorG1068”, page
265
6 - O-ring
leaking
7 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt
by hand to ensure it
is screwed into old
thread. Then tighten
bolt to specified torque.
❑ Specified torques and tightening sequence ⇒ Fig. ““Oil separator - specified torque and tightening
8 - Oil separator
❑ Removing and installing ⇒ a3.2 nd installing oil separator”, page 264
9 - Seal
Oil separator - specified torque and tightening sequence
3. Crankcase ventilation 263

– Tighten bolts in the sequence -1 … 7- to 8 Nm.
3.2 Removing and installing oil separator

Removing
– Remove ignition coils from cylinders “3 and 4” ⇒ a1.2 nd
installing ignition coils”, page 494 .
– Unscrew bolts -arrows-, and push engine lifting eye -1- to
one side.
– If installed, separate electrical connector -1- for crankcase

pressure sensor -G1068-.

– Release hose clip -1- and detach hose from activated char‐
coal filter solenoid valve 1 -N80-.
– Press release tabs on both sides and pull off hose -2- for
crankcase breather.
– Remove bolts -arrows- and detach oil separator.
Installing
• Renew gasket and seals after removal.
494 .
Specified torques
♦ ⇒ Fig. ““Oil separator - specified torque and tightening se‐
quence”“, page 263
3.3 Removing and installing crankcase

pressure sensor -G1068-
Removing
er”, page 76 .
3. Crankcase ventilation 265

– Release fasteners -arrows- and pull off crankcase pressure

sensor -G1068-.
Installing
• Check O-ring in crankcase pressure sensor -G1068- for
damage ⇒ o3.1 verview - crankcase breather system”, page
263 .
page 76 .

4 Oil filter, oil pressure switch

⇒ o4.1 verview - oil filter”, page 267
⇒ o4.2 verview - oil pressure switches/oil pressure control”,
page 267
⇒ a4.3 nd installing oil pressure switch”, page 269
⇒ a4.4 nd installing oil pressure regulating valveN428”, page
271
⇒ a4.5 nd installing piston cooling jet control valveN522”, page
272
⇒ o4.6 il pressure”, page 272
4.1 Assembly overview - oil filter
bracket for ancillaries”,
page 89
2 - Seal
3 - Oil filter element
ling ⇒ o1.2 il:”, page
252
❑ Observe notes ⇒ page
249
4 - O-ring
5 - Oil filter housing
❑ 25 Nm
6 - Oil drain connection
7 - O-ring
leaking
8 - Bolt
Fig. ““Ancillary bracket
- specified torques and
page 79
4.2 Assembly overview - oil pressure switches/oil pressure control
4. Oil filter, oil pressure switch 267

1 - O-ring
2 - Bolt
❑ 4 Nm +90°
3 - Valve for oil pressure con‐
trol -N428-
❑ Checking ⇒ Vehicle di‐
agnostic tester
oil pressure regulating
valveN428”, page 271
4 - Seal
5 - Oil pressure switch for re‐
duced oil pressure -F378-
❑ Brown insulation
agnostic tester
ling oil pressure switch
for reduced oil pressur‐
eF378”, page 269
❑ 20 Nm
6 - Seal
7 - Oil pressure switch -F22-
❑ Blue insulation
agnostic tester
❑ Removing and installing ⇒ a4.3.1 nd installing oil pressure switchF22”, page 269
❑ 20 Nm
8 - O-ring
9 - Bolt
❑ 9 Nm
10 - Piston cooling jet control valve -N522-
❑ Removing and installing ⇒ a4.5 nd installing piston cooling jet control valveN522”, page 272
11 - Seal
12 - Stage 2 oil pressure switch -F446-
❑ Green insulation
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ a4.3.3 nd installing stage 2 oil pressure switchF446”, page 270
❑ 20 Nm

4.3 Removing and installing oil pressure

switch
⇒ a4.3.1 nd installing oil pressure switchF22”, page 269
⇒ a4.3.2 nd installing oil pressure switch for reduced oil pres‐
sureF378”, page 269
⇒ a4.3.3 nd installing stage 2 oil pressure switchF446”, page
270
4.3.1 Removing and installing oil pressure

switch -F22-
Procedure

that escapes.
– Unscrew oil pressure switch -F22- -item 2-.
– Insert new oil pressure switch immediately so that oil loss is
kept to an absolute minimum.
Specified torques
♦ ⇒ o4.2 verview - oil pressure switches/oil pressure control”,
page 267
4.3.2 Removing and installing oil pressure

switch for reduced oil pressure -F378-
Procedure


that escapes.
– Unscrew oil pressure switch for reduced oil pressure -F378-
-item 1-.
Specified torques
page 267
4.3.3 Removing and installing stage 2 oil

pressure switch -F446-
♦ T-bar and socket -T40175-
Procedure
371 .
– Unscrew bolts -arrows- and remove toothed belt guard for

coolant pump.
– Place a cloth underneath to catch escaping engine oil.
– Remove oil pressure switch, stage 2 -F446- -item 2- using
articulated wrench -T40175-.


Specified torques
page 267
♦ ⇒ o2.1 verview - coolant pump, thermostat”, page 290
4.4 Removing and installing oil pressure

regulating valve -N428-
♦ Used oil collection and extraction unit -VAS 6622-
Procedure
insulation.
– Place used oil collection and extraction unit -VAS 6622- un‐
derneath.
– Unscrew bolt -2- and pull off valve for oil pressure control
-N428-. To do this, poly V-belt down slightly.
• Renew O-ring after each removal.
– Insert new valve immediately so that oil loss is kept to an
absolute minimum.

Specified torques
page 267
4.5 Removing and installing piston cooling

jet control valve -N522-
Procedure
fold”, page 406 .

that escapes.
– Unscrew bolts -arrows- and remove piston cooling jet control
valve -N522-.
– Insert new valve immediately so that oil loss is kept to an
absolute minimum.
page 406 .
Specified torques
page 267
4.6 Checking oil pressure

⇒ e4.6.1 ngine oil pressure”, page 272
⇒ o4.6.2 il pressure for piston spray jets”, page 274
4.6.1 Checking engine oil pressure

♦ The oil pump is regulated and has 2 pressure levels. The
pressure levels are checked subsequently.
♦ During the run-in period or emergency running mode of the
engine the oil pump operates only at high pressure level.
♦ The oil pressure depends on the engine oil temperature. At
an engine oil temperature of 80°C the mean value must be
attained approximately.

♦ Oil pressure tester -V.A.G 1342-
♦ T-bar and socket -T40175-
Prerequisites for testing

• Oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Test sequence

that escapes.
– Unscrew oil pressure switch for reduced oil pressure -F378-
-item 1-.
– Screw oil pressure tester -V.A.G 1342- into oil filter bracket
in place of the oil pressure switch.
– Screw oil pressure switch for reduced oil pressure -F378-
into oil pressure tester -V.A.G 1342- and attach connector.
– Start the engine.
• Oil pressure at idling speed: 0.85 to 1.6 bar.

• Oil pressure at 2000 rpm: 1.2 to 1.6 bar.

• Oil pressure at 3700 rpm: 3.0 to 4.0 bar - 2. Compression
stage active, valve for oil pressure control -N428- OK.
– Switch off engine.
Installing
– Install oil pressure switch ⇒ a4.3.2 nd installing oil pressure
switch for reduced oil pressureF378”, page 269 and route
electrical wire carefully.
4.6.2 Checking oil pressure for piston spray

jets
♦ Oil pressure tester -V.A.G 1342-
♦ Test instrument adapter/DSO (2+3-pin) -VAS 5571-
Prerequisites for testing

• Oil level OK.
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Test sequence
– Remove stage 2 oil pressure switch -F446- ⇒ a4.3.3 nd
installing stage 2 oil pressure switchF446”, page 270 .
– Screw oil pressure switch into oil pressure tester -V.A.G
1342-.
– Screw in oil pressure tester -V.A.G 1342- in place of oil
pressure switch.
– Connect test instrument/DSO adapter (2-pin) to oil pressure
switch
– Attach connector for stage 2 oil pressure switch -F446- to
test instrument/DSO adapter (2-pin).

– Check oil pressure ⇒ Vehicle diagnostic tester, stage 2

oil pressure switch F446 .
Installing
– Install stage 2 oil pressure switch -F446- ⇒ a4.3.3 nd instal‐
ling stage 2 oil pressure switchF446”, page 270 .

19 – Cooling
1 Cooling system/coolant
⇒ d1.1 iagram - coolant hoses”, page 276
⇒ c1.2 ooling system for leaks”, page 277
⇒ a1.3 nd adding coolant”, page 281
1.1 Connection diagram - coolant hoses

♦ Blue = large coolant circuit.
♦ Red = small coolant circuit.
♦ Brown = heater circuit.
♦ Green = gearbox coolant circuit.
♦ Arrows = direction of coolant flow.
276 Rep. gr.19 - Cooling

1 - Radiator for engine cool‐

ant
2 - Auxiliary radiator
3 - Radiator outlet coolant
temperature sender -G83-
4 - Actuator for engine tem‐
perature regulation -N493-
5 - Cylinder block/cylinder
head
6 - Restrictor
7 - Auxiliary/supplementary
heater
8 - Coolant expansion tank
9 - Cap
❑ Check pressure relief
valve ⇒ c1.2 ooling sys‐
tem for leaks”, page
277
10 - Non-return valve
11 - Engine oil cooler
12 - Turbocharger
13 - Heat exchanger for heat‐
er
14 - Restrictor
16 - Coolant circulation pump
-V50-
17 - Radiator outlet coolant -
G62-
18 - Restrictor
19 - Coolant pump
20 - ATF cooler
21 - Thermostat
❑ For gearbox coolant circuit
1.2 Checking cooling system for leaks

1. Cooling system/coolant 277

♦ Cooling system tester -V.A.G 1274B-
♦ Adapter for cooling system tester -V.A.G 1274/8-
Procedure
• To perform leakage test correctly, first run a self-test on
cooling system tester -V.A.G 1274B-.
Self-test of cooling system tester -V.A.G 1274B-
– Operate cooling system tester -V.A.G 1274B- several times.

– Build up a pressure of 3.0 bar on cooling system tester.
– Observe pressure on pressure gauge of cooling system test‐

er -V.A.G 1274B- for 30 seconds.
If no pressure builds up or if the pressure drops again:
• Cooling system tester -V.A.G 1274B- is leaking and should
not be used.
Checking cooling system for leaks
• Engine at operating temperature.
• Ignition switched off
CAUTION
pansion tank with cloths and opening it carefully.
– Fit cooling system tester -V.A.G 1274B- with adapter -

V.A.G 1274/8- to coolant expansion tank.

– Build up pressure of approx. 1.5 bar using hand pump of

cooling system tester.
• The pressure cannot drop by more than 0.2 bar within 10 mi‐
nutes.
• The drop of 0.2 bar in pressure within 10 minutes is due to
the cooling of the coolant. The colder the engine, the lower
the pressure drop. If necessary, repeat the check while the
engine is cold.
If pressure drops by more than 0.2 bar:
– Check engine and radiator for leaks and rectify faults.
CAUTION
– Relieve pressure: press pressure relief valve on cooling
system tester until pressure gauge shows value “0”.
Checking pressure relief valve in coolant expansion tank cap
– Fit cooling system tester -V.A.G 1274B- with adapter -

V.A.G 1274/9- onto coolant filler cap (image shows exam‐
ple).
– Build up pressure using hand pump of cooling system tester.
♦ The pressure relief valve must open at a pressure of 1.6 to
1.8 bar.

– Renew filler cap, if pressure relief valve does not open as

described.
1.3 Draining and adding coolant

⇒ c1.3.1 oolant”, page 281
⇒ w1.3.2 ith coolant”, page 282
⇒ c1.3.3 ooling system”, page 288
1.3.1 Draining coolant

♦ Drip tray for workshop hoist -VAS 6208-
♦ Safety goggles
Procedure
CAUTION

insulation.
– Place drip tray for workshop hoist -VAS 6208- underneath.

– Pull out retaining clip -2-, remove lower right coolant hose
from radiator and drain off coolant.
– Re-connect coolant hose ⇒ Fig. ““Connecting coolant hose
with plug-in connector”“, page 317 .
1.3.2 Filling with coolant

♦ Cooling system charge unit -VAS 6096-

♦ Refractometer -T10007A-

Coolant specifications

Note
♦ Due to the differing constitution of tap water in the various

countries and regions, distilled water must be used for mix‐
ing with coolant concentrate.
♦ Only use coolant additives approved for the vehicle ⇒ Elec‐
tronic parts catalogue (ETKA). Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and
corrosion damage as well as scaling. Additives also raise the
boiling point of the coolant. Therefore, the cooling system
must be filled all year round with coolant additive.
♦ Because of its high boiling point, coolant improves engine
reliability under heavy loads, particularly in countries with
tropical climates.
♦ The refractometer -T10007A- or refractometer -T10007B-
must be used to determine the current anti-freeze value.
♦ The scale -1- of the refractometer is calibrated for the cool‐

ant additives G12++ and G12evo.
♦ The scale -2- of the refractometer is calibrated for the cool‐
ant additive G13.
♦ If it cannot be ensured that the same type of coolant additive
is filled: always determine anti-freeze protection using the
scale for G13.
♦ Anti-freeze protection must be guaranteed down to -25°C as
a minimum and, in countries with arctic conditions, down
to approx. -36°C. Increasing the anti-freeze protection is
permissible only if climatic conditions require stronger anti-
freeze protection. It may, however, be increased only to a
maximum of -48°C. Otherwise, the cooling effect will be im‐
paired.
♦ Do not reduce the coolant concentration by adding wa‐
ter even in warmer seasons and in warmer countries. An‐
ti-freeze protection must be guaranteed down to at least
-25°C.

♦ The temperature reading on the refractometer corresponds

to the »ice flocculation point«. Flakes of ice may start form‐
ing in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio

• Coolant (40%) and distilled water (60%) for frost protection
to -25°C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant: ⇒ Electronic Parts Catalogue.
Procedure
– Fill coolant expansion tank of -VAS 6096- with 10 litres of
pre-mixed coolant in correct mixture ratio; mixture ratio ⇒
page 286 .
– To facilitate filling, elevate coolant expansion tank if possi‐
ble, e.g. on a workshop trolley or engine and gearbox jack.
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank.
– Mount cooling system charge unit -VAS 6096- on adapter for
cooling system tester -V.A.G 1274/8-.
– Feed vent hose -2- into a small container -3-.
Please note:
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of
flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 7 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;

needle of gauge must move into green area.
– Also briefly open valve -A- (turn lever in direction of flow to
do this) so that hose on -VAS 6096- coolant reservoir fills
with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in
green range.
– Close valve -B-.
• The needle on the gauge should stop in the green zone.
The vacuum level in the cooling system is then sufficient for
subsequent filling.
• If the needle does not reach the green zone, repeat the
process.
• If the vacuum drops, check the cooling system for leaks.
– Pull off compressed air hose.
– Open valve -A-.
• Vacuum in cooling system causes coolant to be extracted
from -VAS 6096- coolant reservoir and coolant system to be
filled.
– Remove cooling system charge unit -VAS 6096- from cool‐
ant expansion tank.
– Fill coolant up to “max.” mark.
– Install noise insulation ⇒ General body repairs, exterior;

Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.

1.3.3 Bleeding cooling system

♦ Safety goggles
Procedure
– Set temperature regulator to “HI”.
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
– Start engine and run it for max. 2 min. at a speed of approx.
1,500 rpm.
– Fill coolant up to the overflow hole of the coolant expansion
tank while the engine is running.
– Tighten cap -arrow- of coolant expansion tank until it engag‐
es.
– Run engine at idling speed until both large coolant hoses on

radiator are heated up.
– Switch off engine.
Check coolant level.
CAUTION
• When the engine is cold, the coolant level must be between

“min.” and “max” marking.

• The coolant level can be at or above the “max.” mark when

the engine is warm.
– Fill more coolant if necessary.

2 Coolant pump, regulation of cooling

system
⇒ o2.1 verview - coolant pump, thermostat”, page 290
⇒ o2.2 verview - electric coolant pump”, page 292
⇒ o2.3 verview – coolant valves”, page 293
⇒ o2.4 verview - coolant temperature sender”, page 294
⇒ a2.5 nd installing electric coolant pump”, page 295
⇒ a2.6 nd installing coolant pump”, page 298
⇒ a2.7 nd installing toothed belt for coolant pump”, page 299
⇒ a2.8 nd installing actuator for engine temperature regula‐
tionN493”, page 301
⇒ a2.9 nd installing coolant temperature senderG62”, page 304
⇒ a2.10 nd installing radiator outlet coolant temperature send‐
erG83”, page 305
⇒ a2.11 nd installing coolant valves”, page 305
2.1 Assembly overview - coolant pump, thermostat

1 - Connection
2 - O-ring
❑ Qty. 2
3 - Dowel pin
❑ Inserted in cylinder
block
4 - Bolt
Fig. ““Actuator for en‐
gine temperature reg‐
ulation -N493- - tight‐
ening torque and se‐
5 - Seal
6 - Coolant pump
coolant pump”, page
298
❑ New coolant pump: re‐
move protective cap
7 - Bolt
❑ Tightening sequence ⇒
Fig. ““Coolant pump -
specified torque and
page 292
8 - Toothed belt
❑ For coolant pump
❑ Removing and installing ⇒ a2.7 nd installing toothed belt for coolant pump”, page 299
9 - Bolt
❑ 9 Nm
10 - Toothed belt guard
❑ Different versions; for allocation refer to ⇒ Electronic parts catalogue
11 - Bolt
❑ Left-hand thread
❑ 17 Nm
12 - Toothed belt drive sprocket
❑ Installation position: splines point towards balance shaft, inlet side
13 - Seal
❑ Renewing ⇒ o4.2.3 il seal for balance shaft (inlet side)”, page 124
15 - Seal
16 - Actuator for engine temperature regulation -N493-
2. Coolant pump, regulation of cooling system 291

❑ Removing and installing ⇒ a2.8 nd installing actuator for engine temperature regulationN493”, page
301
Actuator for engine temperature regulation -N493- - tightening

torque and sequence

Coolant pump - specified torque and tightening sequence
2.2 Assembly overview - electric coolant pump

1 - Coolant hose
-V50-
electric coolant pump”,
page 295
3 - Retainer
❑ For continued coolant
circulation pump -V50-.
4 - Bolt
❑ 40 Nm
5 - Rubber mounting
6 - Spacer bush
7 - Bolt
❑ 1.5 Nm
8 - Coolant hose
2.3 Assembly overview – coolant valves

1 - Coolant hose
2 - Coolant valve for gearbox
-N488-
ling coolant valves”,
page 305
3 - Nut
❑ 9 Nm
4 - Coolant hose
5 - Bolt
❑ 20 Nm
6 - Bracket
❑ For coolant valve for
gearbox -N488-
2.4 Assembly overview - coolant temperature sender

1 - Retaining clip
❑ Check for firm seating
2 - O-ring
ling radiator outlet cool‐
ant temperature send‐
erG83”, page 305
4 - O-ring
5 - O-ring
leaking
6 - Bolt
❑ 4 Nm +45°
7 - Radiator outlet coolant -
G62-
❑ On cylinder head (gear‐
box end).
ling coolant tempera‐
ture senderG62”, page
304
2.5 Removing and installing electric cool‐

ant pump
♦ Hose clamps to 25mm -3094-

♦ Hose clamp pliers -VAS 6340-
♦ Safety goggles
Removing
• Fit all heat shield sleeves in the same place when installing.
CAUTION


371 .
– Open heat insulation sleeve -3-.

– Clamp off coolant hoses using hose clamps, up to 25mm
-3094-.
– Place a cloth underneath to catch escaping coolant.
– Release hose clips -arrows- and detach coolant hoses.
– Unscrew bolt -2- and remove coolant circulation pump -V50-.
Installing

– Check coolant level ⇒ page 288 .
Specified torques
♦ ⇒ o2.2 verview - electric coolant pump”, page 292
2.6 Removing and installing coolant pump

Removing
371 .
– Unscrew bolts -arrows- and remove toothed belt guard for
coolant pump.
– Remove bolts -1 … 4- and detach coolant pump from actua‐

tor for engine temperature regulation -N493-.
– Remove toothed belt from coolant pump.

Installing


– Install coolant pump -1- and fit toothed belt.
– Ensure correct seating of centring rings -arrows- and seal

-3-.
– After installing a new coolant pump -2-, remove protective
cap -1- from drive sprocket.
Specified torques
♦ ⇒ Fig. ““Coolant pump - specified torque and tightening se‐
2.7 Removing and installing toothed belt

for coolant pump
♦ Torque wrench -V.A.G 1410-

Removing
– Remove radiator cowl ⇒ a4.5 nd installing radiator cowl”,
page 328 .
– Remove stage 2 oil pressure switch -F446- ⇒ a4.3.3 nd
installing stage 2 oil pressure switchF446”, page 270 .
– Counterhold crankshaft on vibration damper with ratchet
ring spanner AF 21 -T40263-, adapter -T40314- and socket
AF 24.


– Loosen bolt on drive sprocket -1- for coolant pump using tor‐
que wrench -V.A.G 1410- and insert tool -T10360- -arrow-,
and unscrew it by 3 turns.
– Remove toothed belt -2-.
Installing
• Note installation position of V-belt pulley ⇒ Item 12 (page
291) .
– Install stage 2 oil pressure switch -F446- ⇒ a4.3.3 nd instal‐
ling stage 2 oil pressure switchF446”, page 270 .
– Install radiator cowl ⇒ a4.5 nd installing radiator cowl”, page
328 .
Specified torques
2.8 Removing and installing actuator for

engine temperature regulation -N493-

Removing
er”, page 76 .
– Remove throttle valve module -GX3- ⇒ a5.3 nd installing
throttle valve moduleGX3”, page 410 .
– Release hose clip -3-, pull out retaining clip -2- and push
front coolant pipe to one side.
– Remove coolant pump ⇒ a2.6 nd installing coolant pump”,

page 298 .
– Lift retaining clips -1, 2-, and remove coolant hoses.
– Separate electrical connector -arrow-.

– Remove bolts -1 to 5-.

– Detach actuator for engine temperature regulation -N493-
from dowel pins, and pull it off engine oil cooler.
Installing
• Renew seals and O-rings after removal.
– Coat O-rings -4- with coolant; coolants ⇒ Electronic Parts
Catalogue.
– Check whether the two dowel pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push actuator for engine temperature regulation -N493-
-item 3- onto connecting piece and dowel pins in cylinder
block and tighten bolts.
– Install coolant pump ⇒ a2.6 nd installing coolant pump”,
page 298 .
– Install throttle valve module -GX3- ⇒ a5.3 nd installing throt‐
tle valve moduleGX3”, page 410 .
– Connect coolant hoses with plug-in connector ⇒ page 317 .
page 76 .

Specified torques
♦ ⇒ Fig. ““Actuator for engine temperature regulation -N493- -
tightening torque and sequence”“, page 292
♦ ⇒ o3.1 verview - coolant pipes”, page 308
2.9 Removing and installing coolant tem‐

perature sender -G62-
Procedure
• Engine cold.
– Briefly open cap -arrow- of coolant expansion tank to reduce
residual pressure in cooling system, and then tighten cap
again until it engages.
– Remove air filter housing ⇒ a4.2 nd installing air filter hous‐

ing”, page 399 .

– Remove bolt -2- and detach coolant temperature sender
-G62- -item 3-.
• Renew O-ring if damaged or leaking.
– Insert new coolant temperature sender immediately so that
coolant loss is kept to an absolute minimum.
– Install air filter housing ⇒ a4.2 nd installing air filter housing”,
page 399 .
Specified torques
♦ ⇒ o2.4 verview - coolant temperature sender”, page 294

2.10 Removing and installing radiator outlet

coolant temperature sender -G83-
Procedure
• Engine cold.
– Briefly open cap -arrow- of coolant expansion tank to reduce
residual pressure in cooling system, and then tighten cap
again until it engages.

insulation.

– Pull out retaining clip -2-, and pull off radiator outlet coolant
temperature sender -G83-.
– Insert new coolant temperature sender immediately so that
coolant loss is kept to an absolute minimum.
– Check retaining clip is secure.
Specified torques
2.11 Removing and installing coolant valves


Removing
page 328 .
– Unclip coolant hose -1- from air intake pipe and push up‐
wards -arrow-.


-3094-.
– Release hose clips and detach coolant hoses.
– Remove nuts -arrows- and detach coolant valve for gearbox
-N488-.
328 .
Specified torques
♦ ⇒ o2.3 verview – coolant valves”, page 293

3 Coolant pipes
⇒ o3.1 verview - coolant pipes”, page 308
⇒ a3.2 nd installing coolant pipes”, page 309
3.1 Assembly overview - coolant pipes
1 - Front coolant pipe

ling front coolant pipe”,
page 309
2 - Bolt
❑ 6 Nm
3 - Bolt
❑ 6 Nm
4 - Upper coolant pipe
ling ⇒ a3.2.2 nd in‐
stalling upper coolant
pipe”, page 311
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
7 - Coolant bleeder line
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
Coolant pipe to radiator cowl - specified torque

– Tighten bolts -arrows- to 5 Nm.

Coolant pipe on gearbox - specified torque
– Tighten bolt -1- and nut -2- to 20 Nm.
3.2 Removing and installing coolant pipes

⇒ a3.2.1 nd installing front coolant pipe”, page 309
⇒ a3.2.2 nd installing upper coolant pipe”, page 311
⇒ a3.2.3 nd installing coolant pipe on radiator cowl”, page 312
⇒ a3.2.4 nd installing coolant pipe on gearbox”, page 314
3.2.1 Removing and installing front coolant

pipe
3. Coolant pipes 309

Removing
– Remove front air intake pipe ⇒ a2.6.1 nd installing air in‐
take pipe for throttle valve module/charge air cooler, DNFC,
DNFE, DNFG, DSFB, DSFE, DSFF”, page 368 .
– Release hose clips -1, 3- and lift retaining clip -2- before
removing coolant hoses.
– Remove front coolant pipe.
Installing

– Install front air intake pipe ⇒ a2.6.1 nd installing air intake

pipe for throttle valve module/charge air cooler, DNFC,
Specified torques
3.2.2 Removing and installing upper coolant

pipe
Removing
– Remove ignition coil from cylinder “3” ⇒ a1.2 nd installing
ignition coils”, page 494 .
– Free off wiring harness from clip -1-.

– Release fasteners -arrows- and detach wiring duct -3- from

bracket.
– Unscrew bolts -2-.
-3094-.

– Unscrew bolts -1- and remove upper coolant pipe.
Installing
– Install ignition coil ⇒ a1.2 nd installing ignition coils”, page
494 .
Specified torques
3.2.3 Removing and installing coolant pipe

on radiator cowl

Removing
-3094-.
– Unscrew bolts -arrows- and remove coolant pipe.

Installing
Specified torques
♦ ⇒ Fig. ““Coolant pipe to radiator cowl - specified torque”“,
page 308

3.2.4 Removing and installing coolant pipe

on gearbox
Removing
insulation.
ing”, page 399 .
-3094-.


– Unscrew bolt -1- and nut -2- and remove coolant pipe.
Installing
page 399 .
Specified torques
♦ ⇒ Fig. ““Coolant pipe on gearbox - specified torque”“, page
309

4 Radiator, radiator fan

⇒ o4.1 verview - radiator/radiator fan”, page 316
⇒ o4.2 verview – radiator cowl and radiator fan”, page 319
⇒ o4.3 verview - auxiliary radiator”, page 321
⇒ a4.4 nd installing radiator”, page 322
⇒ a4.5 nd installing radiator cowl”, page 328
⇒ a4.6 nd installing radiator fan”, page 333
⇒ a4.7 nd installing auxiliary radiator”, page 334
4.1 Assembly overview - radiator/radiator

fan
⇒ o4.1.1 verview – radiator/radiator fan, Golf, Tiguan, Arteon,
T-Roc, Passat”, page 316
⇒ o4.1.2 verview - radiator, Polo”, page 318
4.1.1 Assembly overview – radiator/radiator fan, Golf, Tiguan, Arteon, T-Roc,

Passat

1 - Retaining clip
❑ For radiator outlet cool‐
ant temperature sender
-G83-.
2 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ Fig. ““Con‐
necting coolant hose
with plug-in connec‐
tor”“, page 317
3 - O-ring
leaking
ling radiator outlet cool‐
ant temperature send‐
erG83”, page 305
ant
radiator”, page 322
❑ Renew coolant after re‐
placing
6 - O-ring
leaking
7 - Coolant hose
❑ Pull out retaining clip to remove
❑ Connect ⇒ Fig. ““Connecting coolant hose with plug-in connector”“, page 317
8 - Coolant hose
Connecting coolant hose with plug-in connector
– Renew retaining clip -4- if damaged.
4. Radiator, radiator fan 317

– Renew damaged O-ring. To do this, remove O-ring -2- from

plug-in connector -3- using a suitable tool (do not use sharp
implement). Ensure that plug-in connector and O-ring seat
are not damaged in the process.
– Moisten new O-ring with coolant.
– Press plug-in connector -3- on connection -1- until it engag‐
es audibly.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
4.1.2 Assembly overview - radiator, Polo
1 - Charge air cooler

ling ⇒ page 363
2 - Sealing strip
ant
ling ⇒ page 322
4 - Coolant hose
❑ Pull out retaining clip to
remove
❑ Connect ⇒ page 319
5 - O-ring
❑ Renew if damaged
6 - Radiator mounting
7 - Bolt
❑ For radiator mounting
❑ 5 Nm
8 - Bolt
❑ For assembly frame
❑ 5 Nm
9 - Air duct
10 - Condenser
ling ⇒ Heating, air con‐
ditioning; Rep. gr. 87;
Refrigerant circuit; Re‐
moving and installing
condenser
11 - O-ring
12 - Radiator outlet coolant temperature sender -G83-
❑ Removing and installing ⇒ page 305
13 - Rubber mounting
❑ For charge air cooler

Connecting coolant hose with plug-in connector
– Remove O-ring -2- in coolant hose -3- if damaged.

– Moisten O-ring with coolant, and insert it into coolant hose.
– Push coolant hose onto coolant pipe -1- until it audibly en‐
gages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
4.2 Assembly overview – radiator cowl and

radiator fan
⇒ o4.2.1 verview - radiator cowl and radiator fan, twin fan”,
page 319
⇒ o4.2.2 verview - radiator cowl and radiator fan, single fan”,
page 320
4.2.1 Assembly overview - radiator cowl and radiator fan, twin fan

1 - Bolt
❑ 5 Nm
2 - Radiator cowl
ling ⇒ page 328
3 - Bolt
❑ 5 Nm
4 - Radiator fan -V7-
ling ⇒ page 333
5 - Radiator fan 2 -V177-
ling ⇒ page 333
4.2.2 Assembly overview - radiator cowl and radiator fan, single fan

1 - Bolt
❑ 5 Nm
2 - Radiator cowl
ling ⇒ page 328
3 - Radiator fan -V7-
ling ⇒ page 333
4.3 Assembly overview - auxiliary radiator

1 - Air duct
2 - Protective grille
3 - Bolt
❑ 3.5 Nm
4 - Washer
6 - Nut
❑ 20 Nm
8 - Hose retainer
9 - Coolant hoses
10 - Hose retainer
11 - Nut
❑ 20 Nm
12 - Bracket
❑ For additional cooler
13 - Auxiliary radiator
❑ In event of minor dents
in fins ⇒ r3.6 adiator
and condensers”, page
7
auxiliary radiator”, page
334
❑ Renew coolant after re‐
placing
4.4 Removing and installing radiator

⇒ a4.4.1 nd installing radiator, Golf, Tiguan, Arteon, T-Roc,
Passat”, page 322
⇒ a4.4.2 nd installing radiator, Polo”, page 324
4.4.1 Removing and installing radiator, Golf,

Tiguan, Arteon, T-Roc, Passat
Removing
ing”, page 399 .
page 328 .
– Lift retaining clip -arrow- and disconnect coolant hose (top
left) from radiator.

NOTICE
Risk of damage to fasteners from improper handling.
– Release fasteners with care.
– Carefully release retaining tab -4- using angle driver with

hexagon bit AF 6 -item 2- and socket AF 6 -item 1- -arrow-.
– Pull radiator -3- backwards slightly off charge air cooler.
– Repeat procedure on opposite side and remove radiator.
Installing
• If there are minor dents in the fins, refer to respective in‐
structions ⇒ r3.6 adiator and condensers”, page 7 .
• Replace damaged O-rings.
328 .
page 399 .
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“, page 317 .

Specified torques
♦ ⇒ o4.1 verview - radiator/radiator fan”, page 316
♦ ⇒ o4.1 verview – air filter housing”, page 397
4.4.2 Removing and installing radiator, Polo

♦ Drip tray for workshop hoist -VAS 6208-
Note
The radiator is removed together with the charge air cooler.
Removing
– Remove radiator cowl ⇒ page 328 .
– Drain coolant ⇒ page 322 .
– Release retaining clip -arrow-.
– Pull off upper left coolant hose -1-.

– Push radiator upwards slightly towards engine and remove
sealing strips -1- on both sides.

– Release retaining clips -1- in direction of -arrow A- at top left

and right.
– Pull condenser -3- upwards from mountings -arrows B-.

– Secure condenser to lock carrier.
– Lift radiator with charge air cooler upwards off mountings
-arrows-. Pull down lock carrier in area of mountings if nec‐
essary.

Installing
– Fit radiator mounting -1- onto charge air cooler. When doing
so, note the installation position -arrow-.
– Insert radiator with charge air cooler in mountings -arrows-
in lock carrier. Pull down lock carrier in area of mountings if
necessary.
– Attach radiator cowl to radiator and engage. Ensure proper

engagement by pulling.
– Swing radiator cowl and charge air cooler together with ra‐
diator into lock carrier. Ensure proper seating of radiator
mountings in lock carrier.
– Attach condenser to charge air cooler and engage.
– Secure sealing strip on right as shown.

– Secure sealing strip on left as shown.
– If fastener was cut off, bolt radiator mountings to lock carrier.

Bolts -2- ⇒ Electronic parts catalogue (ETKA).
– Install assembly frame -1- ⇒ General body repairs, exterior;

Rep. gr. 50; Lock carrier, Assembly overview - lock carrier.

– Connect coolant hose with plug-in connector ⇒ page 319 .

– Reset service position ⇒ General body repairs, exterior;
Rep. gr. 50; Lock carrier; Moving to and back from service
position.
– Add coolant ⇒ page 288 .
Note
♦ Hose connections as well as hoses for charge air system

must be free of oil and grease when installing.
♦ Secure all hose connections with the correct type of hose
logue (ETKA).
♦ In order to be in a position to securely attach the charge air
hoses on their connections, the worm screws of the used
hose clips have to the sprayed with penetrating spray before
installing.
Specified torques
Component Specified torque
Radiator mounting to lock carrier 5 Nm
4.5 Removing and installing radiator cowl

⇒ a4.5.1 nd installing radiator cowl, Golf, Tiguan, Arteon, T-Roc,
Passat”, page 328
⇒ a4.5.2 nd installing radiator cowl, Polo”, page 330
4.5.1 Removing and installing radiator cowl,

Golf, Tiguan, Arteon, T-Roc, Passat
Removing
– Unscrew bolts -arrows- and push coolant pipe on lock carrier
backwards.


insulation.
– Release hose clips -1, 2- and remove air intake hose.
CAUTION
Danger of injury; the radiator fans can run at any time.
– Disconnect electrical connectors.
– Unplug electrical connector -1- for radiator fan (push retainer

in direction of -arrow A- and press release catch down).

– Press locking tabs on left and right of radiator cowl simulta‐

neously -arrow B-, pull radiator cowl upwards off radiator,
Installing
Specified torques
♦ ⇒ Fig. ““Coolant pipe to radiator cowl - specified torque”“,
page 308
4.5.2 Removing and installing radiator cowl,

Polo
Rep. gr. 66; Noise insulation; Assembly overview – noise
insulation.
– Release hose clip -1- and -2-, and remove right charge air
hose.
– Open hose clip -arrow- on charge air cooler and pull off left
charge air hose -A- from charge air cooler.
– Bring lock carrier into service position ⇒ General body re‐

pairs, exterior; Rep. gr. 50; Lock carrier - bringing lock carri‐
er into service position and moving it back.
– Remove assembly frame -1- ⇒ General body repairs, exte‐
rior; Rep. gr. 50; Lock carrier, Assembly overview - lock
carrier.

– Using diagonal pliers, pinch off fasteners -arrows- for radia‐

tor mounting on left and right.
Note
The radiator mounting will be reused when reinstalling the radi‐

ator. It will then be bolted to lock carrier. For bolts, refer to
⇒ Electronic parts catalogue (ETKA).
– Separate connector -1- for radiator fan.
– Push radiator at top towards engine.

– Push locking tabs -2- for radiator cowl on left and right side
-arrow-. Pull radiator cowl upwards -arrow B-.

– Take out radiator cowl -3- upwards.

– Cover radiator with protective mat -VAS 531 003- before
continuing work.
Installing
– Push radiator for engine coolant upwards towards engine,

attach radiator cowl to radiator and engage. Ensure proper
engagement by pulling.
– Swing radiator into lock carrier and bolt radiator mounting -1-
to lock carrier. Bolts -2- ⇒ Electronic parts catalogue (ETKA).
– Reset service position ⇒ General body repairs, exterior;
Rep. gr. 50; Lock carrier; Moving to and back from service
position.
Further assembly is carried out in the reverse order of removal.
Specified torques
Radiator mounting to lock carrier 5 Nm

4.6 Removing and installing radiator fan

⇒ a4.6.1 nd installing radiator fan, twin fan”, page 333
⇒ a4.6.2 nd installing radiator fan, single fan”, page 333
4.6.1 Removing and installing radiator fan,

twin fan
Removing
Note
Attach cable ties in all the same places when installing.

– Unclip electrical connector -7-.

– Unscrew and remove bolts -1- for radiator fan -2-.
– Unscrew and remove bolts -5- for radiator fan -4-.
Installing
– Install radiator cowl ⇒ page 328 .
Specified torques
♦ ⇒ o4.2 verview – radiator cowl and radiator fan”, page 319
4.6.2 Removing and installing radiator fan,

single fan
Removing
Note
Reinstall all cable ties in the same locations when installing.

– Disconnect electrical connector.

– Unscrew bolts -arrows- and remove radiator fan -V7-.

Installing
– Install radiator cowl ⇒ page 328 .
Specified torques
♦ ⇒ o4.2 verview – radiator cowl and radiator fan”, page 319
4.7 Removing and installing auxiliary radia‐

tor
Removing
insulation.

– Remove front left wheel housing liner ⇒ General body re‐

overview – front wheel housing liner.
– Remove front right air intake grille ⇒ General body repairs,
exterior; Rep. gr. 63; Front bumper; Assembly overview -
bumper cover.
– Carefully unclip air duct -1- from radiator -arrow- and leave
in installation position.

-3094-.
– Release hose clips -3-, disconnect coolant hoses and free
off from hose retainer -1-.
– Unscrew nuts -arrows- and remove auxiliary radiator -4- to‐
gether with bracket -2-.
– Unscrew bolts -5- and remove auxiliary radiator from brack‐
et.
Installing
• Secure all hose connections with the correct type of hose
logue (ETKA).


Specified torques
♦ ⇒ o4.3 verview - auxiliary radiator”, page 321

21 – Turbocharging/supercharging
1 Turbocharger
⇒ o1.1 verview – turbocharger”, page 337
⇒ a1.2 nd installing turbocharger”, page 347
⇒ a1.3 nd installing charge pressure control moduleGX34”,
page 353
⇒ a1.4 nd installing sender 1 for turbocharger speedG688,
DNFC, DNFE, DNFG, DSFB, DSFE, DSFF”, page 355
1.1 Assembly overview – turbocharger

⇒ o1.1.1 verview – turbocharger, DNFC, DNFE, DNFG, DSFB,
DSFE, DSFF”, page 337
⇒ o1.1.2 verview – turbocharger, DNPA, DNNA, DNND, DRNA”,
page 342
1.1.1 Assembly overview – turbocharger,

DNFC, DNFE, DNFG, DSFB, DSFE,
DSFF
♦ Assembly overview – turbocharger, part 1 ⇒ page 337
♦ Assembly overview – turbocharger, part 2 ⇒ page 339
Assembly overview – turbocharger part 1
1. Turbocharger 337
1 - Seal
2 - Nut
❑ Coat studs with high-
temperature paste
logue
Fig. ““Turbocharger -
specified torque and
page 341
3 - Locking plate
❑ Qty. 2
❑ Installing ⇒ Fig. ““In‐
stalling tab washers”“,
page 341
4 - Turbocharger
ling ⇒ a1.2 nd in‐
stalling turbocharger”,
page 347
5 - Oil supply line
6 - O-ring
7 - Bolt
❑ 9 Nm
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
10 - O-ring
11 - Bolt
❑ 9 Nm
12 - Union
13 - O-ring
14 - O-ring
15 - Coolant supply line
16 - Bolt
❑ 9 Nm
338 Rep. gr.21 - Turbocharging/supercharging

1. Turbocharger 339
1 - Bolt
❑ 9 Nm
2 - Oil return line
3 - O-ring
4 - Bolt
❑ 9 Nm
5 - O-ring
6 - Sender 1 for turbocharger
speed -G688-
7 - Bolt
❑ 4 Nm
8 - O-ring
9 - Seal
10 - Venturi nozzle
11 - Bolt
❑ 9 Nm
12 - O-ring
13 - Turbocharger
ling ⇒ a1.2 nd in‐
stalling turbocharger”,
page 347
14 - Bolt
❑ 9 Nm
15 - Nut
❑ 8 Nm
16 - Ball socket
17 - Securing spring
18 - Control rod
19 - Nut
❑ 8 Nm
20 - Ball socket
22 - Charge pressure control module -GX34-
❑ Consisting of
♦ Charge pressure positioner -V465-

♦ Position sender for charge pressure positioner -G581-

❑ Before removing charge pressure control module -GX34- from turbocharger, ensure that this item is
available on its own ⇒ Electronic parts catalogue.
❑ Removing and installing ⇒ a1.3 nd installing charge pressure control moduleGX34”, page 353
23 - Bolt
❑ 9 Nm
24 - Coolant distribution housing
25 - Bolt
❑ 9 Nm
26 - O-ring
Turbocharger - specified torque and tightening sequence
• Renew nuts after removal.

– Tighten nuts in stages in the sequence shown:
Stage Nuts Specified torques
2 -1, 2- 10 Nm
3 -3, 4- 25 Nm
4 -1, 2- 25 Nm
Installing tab washers
1. Turbocharger 341
• Be aware of teeth deformation.

The tab washers are pressed onto the nuts using the following
tools:
♦ Assembly lever
♦ 1/
2” bit AF 14
♦ Hammer
♦ Ring spanner AF 14
– Press on tab washers at easily accessible nuts using 1/2” bit
AF 14 and hammer.
– Where accessibility to nuts is poor, press on tab washers
using ring spanner AF 14 and assembly lever. Support as‐
sembly lever on turbocharger when doing this.
1.1.2 Assembly overview – turbocharger,

DNPA, DNNA, DNND, DRNA
Assembly overview – turbocharger, part 1 ⇒ page 342
Assembly overview – turbocharger, part 2 ⇒ page 344

1 - O-ring
2 - Venturi nozzle
3 - Bolt
❑ 9 Nm
4 - O-ring
5 - Union
6 - Bolt
❑ 9 Nm
7 - O-ring
8 - Bolt
❑ 9 Nm
9 - Turbocharger air recircula‐
tion valve -N249-
10 - Turbocharger
ling ⇒ page 347
6
11 - Bolt
❑ 9 Nm
12 - Ball socket
14 - Nut
❑ 8 Nm
15 - Control rod
16 - Nut
❑ 8 Nm
18 - Ball socket
19 - Charge pressure control module -GX34-
❑ Consisting of
♦ Charge pressure positioner -V465-
♦ Position sender for charge pressure positioner -G581-
❑ Before removing charge pressure control module -GX34- from turbocharger, ensure that this item is
available on its own ⇒ Electronic parts catalogue.
❑ Removing and installing ⇒ a1.3 nd installing charge pressure control moduleGX34”, page 353
20 - Connection
21 - Bolt
1. Turbocharger 343
❑ 9 Nm
22 - Hose clamp
23 - Charge air hose

1 - Bolt
❑ 9 Nm
2 - O-ring
3 - Washer
4 - Nut
❑ Qty. 4
❑ Coat studs with high-
temperature paste
logue
page 345
5 - Locking plate
❑ Qty. 2
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
8 - Bolt
❑ 9 Nm
9 - Coolant distribution hous‐
ing
10 - Centre hex stud
❑ 9 Nm
11 - Nut
❑ 10 Nm
12 - Oil supply line
13 - Coolant supply line
14 - Bolt
❑ 9 Nm
15 - Seal
16 - Stud
❑ Coat thread with high-temperature paste ⇒ Electronic parts catalogue (ETKA).
❑ 27 Nm
17 - Bolt
❑ 9 Nm
18 - Turbocharger
Turbocharger - specified torque and tightening sequence
1. Turbocharger 345

– Tighten nuts in stages in the sequence shown:
Stage Nuts Specified torques
2 -1, 2- 10 Nm
3 -3, 4- 25 Nm
4 -1, 2- 25 Nm
Installing tab washers
• Be aware of teeth deformation.

The tab washers are pressed onto the nuts using the following
tools:
♦ Assembly lever
♦ 1/
2” bit AF 14
♦ Hammer
♦ Ring spanner AF 14
– Press on tab washers at easily accessible nuts using 1/2” bit
AF 14 and hammer.
– Where accessibility to nuts is poor, press on tab washers
using ring spanner AF 14 and assembly lever. Support as‐
sembly lever on turbocharger when doing this.

1.2 Removing and installing turbocharger

Removing
• Observe rules for cleanliness ⇒ f3.1 or cleanliness”, page 6 .
• If turbocharger has mechanical damage, be aware of foreign
objects in engine ⇒ o3.3 bjects in engine”, page 7 .
• The procedure may differ slightly depending on the turbo‐
charger is installed.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27; Bat‐
tery; Removing and installing battery tray.
– Remove Lambda probe 1 before catalytic converter -GX10-
⇒ a9.2 nd installing Lambda probe”, page 435 .
371 .
– Remove ignition coils from cylinders “2, 3, 4” ⇒ a1.2 nd
installing ignition coils”, page 494 .
– Disconnect connector -2- for sender 1 for turbocharger
speed -G688-.
1. Turbocharger 347

G1037-
valve -N290-
shaft adjustment.
– Remove cam adjustment actuators for cylinders 2 to 4 ⇒
a4.3 nd installing actuators for camshaft adjustment”, page
233 .

NOTICE

line to one side.
– Unscrew bolt -1- and remove screw-type clip.
– Loosen bolt -2-, detach catalytic converter at top and push to

one side (shown with engine removed).
– Release hose clips -2- and detach hoses.
1. Turbocharger 349
– Unscrew bolt -1- and free off control lines.

– Unscrew bolts -arrows- and nuts -1- and remove heat shield.
– Unscrew bolts -arrows- and remove pressure differential

sender for particulate filter -G1037- with bracket.


sides and remove Venturi nozzle.
– Unscrew bolts -arrows- and push oil supply line -1- to one
side.
– Unscrew bolts -arrows-, pull off coolant connection -1- and

oil return line -2-.
– Disconnect connector -1- for charge pressure control module

-GX34- and lay aside.
– Lever off tab washers -1, 2- and discard.
1. Turbocharger 351
– Unscrew nuts -1 to 4-.
– Take off turbocharger from cylinder head and remove up‐

wards.
Installing
• Renew seals, gaskets, O-rings and self-locking nuts after
removal.
• If installed, check O-ring in crankcase pressure sensor -
G1068- for damage ⇒ o3.1 verview - crankcase breather
system”, page 263 .
• Lubricate threaded pins of turbocharger with high-tempera‐
ture paste ⇒ Electronic parts catalogue.
• Fill turbocharger with engine oil at connection for oil supply
line.
– Install tab washers ⇒ Fig. ““Installing tab washers”“, page
341 .
– Install catalytic converter ⇒ page 475 .
– Install cam adjustment actuators ⇒ a4.3 nd installing actua‐
tors for camshaft adjustment”, page 233 .
494 .

– Install Lambda probe 1 before catalytic converter -GX10- ⇒

a9.2 nd installing Lambda probe”, page 435 .
– Install battery tray ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery tray.
• After installing turbocharger, run engine for about 1 minute
at idling speed. Do not rev up immediately to ensure that the
turbocharger is fully primed with oil.
Adaptations must be carried out after renewing turbocharger
with charge pressure control module ⇒ d3.2 iagnoses”, page 6 .
Specified torques
1.3 Removing and installing charge pres‐

sure control module -GX34-
Before removing charge pressure control module -GX34- from
turbocharger, ensure that this item is available on its own
⇒ Electronic parts catalogue.
Removing
er”, page 76 .
– Release hose clips -1, 2- and remove air intake pipe.
– Release fasteners -arrows-, separate air intake hose.
1. Turbocharger 353
Engine codes DNFC, DNFE, DNFG, DSFE:

All:
– Disconnect electrical connector -1- and move clear.
– Free off electrical wire.
– Unscrew bolt -top arrow-, pull off coolant connection -1-.

– Using a small screwdriver, lift up retaining clip -2- slightly
and pull off control rod from ball stud.

– Unscrew bolts -arrows- and remove charge pressure control

module -GX34- -item 1-.
Installing
– Push control rod onto ball stud until it audibly engages.
page 76 .
Adaptations must be carried out after renewing charge pressure
control module ⇒ d3.2 iagnoses”, page 6 .
Specified torques
1.4 Removing and installing sender 1 for

turbocharger speed -G688-, DNFC,
DNFE, DNFG, DSFB, DSFE, DSFF
Removing
er”, page 76 .

1. Turbocharger 355
– Unscrew bolt -1- and remove sender 1 for turbocharger

speed -G688-.
Installing
page 76 .
Specified torques

2 Charge air system

⇒ o2.1 verview – charge air system”, page 357
⇒ o2.2 verview - charge-air hose connections”, page 362
⇒ a2.3 nd installing charge air cooler”, page 363
⇒ a2.4 nd installing charge pressure senderG31”, page 367
⇒ a2.5 nd installing turbocharger air recirculation valveN249,
DNFC, DNFE, DNFG, DSFB, DSFE, DSFF”, page 368
⇒ a2.6 nd installing air intake pipe”, page 368
⇒ c2.7 harge air system for leaks”, page 373
2.1 Assembly overview – charge air sys‐

tem
⇒ o2.1.1 verview – charge air system, DSFB, DSFE, DSFF,
DNFC, DNFE, DNFG”, page 357
⇒ o2.1.2 verview - charge air system, DNPA, DNNA, DRNA,
DNND”, page 359
⇒ o2.1.3 verview - charge air system, Polo”, page 361
2.1.1 Assembly overview – charge air system, DSFB, DSFE, DSFF, DNFC,
DNFE, DNFG
• Before carrying out tests or repairs, check all air intake pipes
and hoses to ensure that they are firmly seated and not
leaking.
2. Charge air system 357

1 - Retaining clips
2 - O-ring
leaking
3 - Air intake hose
4 - Air intake hose
❑ Must be free of oil
and grease before in‐
stalling.
5 - Left air pipe
ling air intake pipe be‐
tween turbocharger and
charge air cooler”, page
371
stalling.
6 - Rubber mounting
7 - Bolt
❑ 7 Nm
8 - Spacer sleeve
9 - Air intake hose
stalling.
❑ If there are minor dents
in the fins, refer to re‐
spective instructions ⇒
r3.6 adiator and con‐
densers”, page 7 .
❑ Removing and installing ⇒ a2.3 nd installing charge air cooler”, page 363
11 - Air duct
12 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt by hand to ensure it is screwed into old thread. Then tighten bolt to specified
torque.
❑ 5.5 Nm
15 - Air duct
16 - Air intake hose
❑ Must be free of oil and grease before installing.
18 - Front air pipe
❑ Removing and installing ⇒ a2.6.1 nd installing air intake pipe for throttle valve module/charge air
cooler, DNFC, DNFE, DNFG, DSFB, DSFE, DSFF”, page 368

19 - Spacer sleeve
20 - Bolt
❑ 7 Nm
22 - Bolt
❑ 5 Nm
23 - Charge air pressure sender -G31-
❑ Removing and installing ⇒ a2.4 nd installing charge pressure senderG31”, page 367
24 - O-ring
25 - O-ring
26 - Turbocharger air recirculation valve -N249-
❑ Removing and installing ⇒ a2.5 nd installing turbocharger air recirculation valveN249, DNFC, DNFE,
DNFG, DSFB, DSFE, DSFF”, page 368
27 - Bolt
❑ 5 Nm
2.1.2 Assembly overview - charge air system, DNPA, DNNA, DRNA, DNND
Note
♦ Installing screw-type clips for charge air hose connections ⇒ page 362 .
♦ Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs.

1 - Air intake pipe

ling ⇒ page 371
2 - Grommet
3 - Spacer sleeve
4 - Bolt
❑ 7 Nm
5 - Charge air hose
ling ⇒ page 368
6 - Sealing strip
ling ⇒ page 363
Note
If there are minor dents in the fins,

refer to ⇒ page 7 .
8 - Sealing strip
9 - Rubber mounting
❑ for charge air cooler
11 - Bolt
❑ 7 Nm
12 - Spacer sleeve
13 - Grommet
14 - Bolt
❑ 5 Nm
16 - O-ring

❑ Renew
18 - Air intake pipe
2.1.3 Assembly overview - charge air system, Polo
Note
♦ Installing screw-type clips for charge air hose connections ⇒ page 362 .
♦ Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs.
1 - Air intake pipe

2 - Air intake pipe
❑ Turbocharger/charge
air cooler
ling ⇒ page 371
3 - Grommet
4 - Spacer sleeve
5 - Bolt
❑ 7 Nm
6 - Charge air hose
ling ⇒ page 363
❑ If there are minor dents
in the fins, refer to ⇒
page 7
8 - Rubber mounting
9 - Grommet
10 - Bolt
❑ 7 Nm
11 - Spacer sleeve
12 - Bolt
❑ 5 Nm
13 - Charge air pressure
sender -G31-
ling ⇒ page 367
14 - O-ring

2.2 Assembly overview - charge-air hose

connections
• Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
• In order to be able to securely attach the air intake hoses
on their connections, spray the worm screws of the used
screw-type clips with rust remover before installing.
Specified torques for
1- Hose clip -a- = 12 mm wide: 5.5 Nm

2- Hose clip -b- = 9 mm wide: 3.4 Nm
Hose clips on pressure side have barbs -arrows-.
• To remove air intake hose, screw-type clip must be suffi‐

ciently loosened.
• Loosened screw-type clips can be reused.
• Screw-type clip -1- with barbs -arrows- must not be pulled off
air intake hose.

• If screw-type clip with barbs is pulled off air intake hose, air
intake hose must be renewed.
• New air intake hose is supplied with screw-type clip already
mounted.
2.3 Removing and installing charge air

cooler
⇒ a2.3.1 nd installing charge air cooler, Golf, Tiguan, Arteon,
T-Roc, Passat”, page 363
⇒ a2.3.2 nd installing charge air cooler, Polo”, page 366
2.3.1 Removing and installing charge air

cooler, Golf, Tiguan, Arteon, T-Roc,
Passat
Removing
– Remove front bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Front bumper; Removing and installing
bumper cover.
– Remove refrigerant lines from condenser ⇒ Heating, air con‐
ditioning; Rep. gr. 87; Refrigerant circuit; Disconnecting and
connecting refrigerant lines on condenser.
– Removing radiator ⇒ a4.4 nd installing radiator”, page 322 .

Radiator mounting with fastener:
– Cut through fasteners -arrows- on left and right of radiator

mounting using side cutters and push radiator together with
cooler for charge air cooling circuit back slightly. (Radiator
mounting can be reused.)
Radiator mounting with threaded connection:
– Unscrew bolt on left and right -arrow- and push radiator

together with charge air cooler back slightly.

Continuation:
– Release air duct on left and right -1- at bottom of charge air
cooler -arrow A- and detach upwards at top -arrow B-.
– Release fasteners on left and right -1- -arrow A- and disen‐
gage condenser -3- from charge air cooler -2-.
– Remove condenser.
– Take out charge air cooler from underneath.
Installing
– Installing radiator ⇒ a4.4 nd installing radiator”, page 322 .
– Install refrigerant lines ⇒ Heating, air conditioning; Rep.
gr. 87; Refrigerant circuit; Disconnecting and connecting re‐
frigerant lines on condenser.

– Install front bumper cover ⇒ General body repairs, exterior;

Rep. gr. 63; Front bumper; Removing and installing bumper
cover.
Specified torques
2.3.2 Removing and installing charge air

cooler, Polo
Note
The charge air cooler is removed with radiator.
Removing
– Remove radiator ⇒ page 322 .
Note
In order to avoid damage to charge air cooler, 2 mechanics

should be used to disconnect charge air cooler from radiator.
– Release catches on charge air cooler -1- -arrows A-.
– Pull radiator -2- for coolant off charge air cooler -arrow B-.
– Push charge air cooler -1- towards the right out of the lock‐
ing latch of the radiator -2-.

Installing
Install in reverse order of removal. In the process, observe the
following:
– Engage charge air cooler in mountings on radiator. Ensure
proper engagement by pulling.
2.4 Removing and installing charge pres‐

sure sender -G31-
Removing
insulation.
– Unscrew bolt -1-, pull out charge pressure sender -G31-

from air intake pipe.
Installing
Specified torques

2.5 Removing and installing turbocharger

air recirculation valve -N249-, DNFC,
DNFE, DNFG, DSFB, DSFE, DSFF
Removing
ing”, page 399 .
page 328 .
– Unscrew bolts -arrows- and remove turbocharger air recircu‐

lation valve -N249-.
Installing
328 .
page 399 .
Specified torques
2.6 Removing and installing air intake pipe

⇒ a2.6.1 nd installing air intake pipe for throttle valve mod‐
DSFF”, page 368
⇒ a2.6.2 nd installing air intake pipe for throttle valve mod‐
ule/charge air cooler, DNPA, DNNA, DNND, DRNA ”, page 370
⇒ a2.6.3 nd installing air intake pipe between turbocharger and
charge air cooler”, page 371
2.6.1 Removing and installing air intake pipe

for throttle valve module/charge air
cooler, DNFC, DNFE, DNFG, DSFB,
DSFE, DSFF

Removing
ing”, page 399 .
page 328 .
1 - For charge pressure sender -G31-.

5 - For turbocharger air recirculation valve -N249-.

– Free off coolant hose from retaining clip -6-.
– Remove front air intake pipe -2-, guiding air intake hose -4-
when doing so.
Installing
328 .
page 399 .
Specified torques

for throttle valve module/charge air
cooler, DNPA, DNNA, DNND, DRNA
– Remove air duct on lock carrier ⇒ page 401 .
– Remove noise insulation -1- ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Noise insulation; Assembly overview - noise
insulation.
– Release hose clip -2-, and pull charge air hose off charge air
cooler.

Note
Disregard -item 1-.

– Pull connector -1- off charge pressure sender -G31-.

– Release hose clip -2- on charge air hose, and pull charge air
hose off throttle valve module -GX3-.
– Remove air intake hose downwards.

between turbocharger and charge air
cooler
Removing
ing”, page 399 .
insulation.

– Lay aside wiring harness -1- and -2-.

– Battery in engine compartment: remove battery ⇒ Electrical
system; Rep. gr. 27; Battery; Removing and installing bat‐
tery.
– Move clear wiring harnesses -1- at air intake pipe.
– Loosen screw-type clip -2-.

– Remove air intake pipe -4- upwards.
Installing
page 399 .

Specified torques
2.7 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687-
♦ Plug -V.A.G 1687/6-
♦ Adapter -V.A.G 1687/18-1-

♦ Ultrasonic tester -V.A.G 1842S-
♦ Leak detector spray, commercially available

Procedure
er”, page 76 .


– Connect plug -V.A.G 1687/6- -item 2- with adapter -V.A.G
1687/18-1- -item 1- to turbocharger.
– Connect charge air system tester -V.A.G 1687- -item 3- to

adapter.
Prepare charge air system tester -V.A.G 1687-:
– Pull pressure control valve -2- upwards, unscrew it com‐

pletely, and close valves -3- and -4-.
– Connect charge air system tester -V.A.G 1687- to com‐
pressed air -1- via commercial adapter.
– If there is water in inspection glass, drain it via water drain
plug -6-.

– Open valve -3-.
NOTICE
Risk of component damage if test pressure is set too high.
– Never set test pressure higher than prescribed.
– Adjust pressure to 0.2 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary,
re-adjust pressure to 0.2 bar.
– Open cap on oil filler neck.
– Check charge air path for leaks:
♦ by listening, also at oil filler neck
♦ by feeling
♦ Using commercially available leak detector spray
♦ Using ultrasonic tester -V.A.G 1842S-, see ⇒ operating in‐
structions for use.
Please note:
A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
Installing
Assembly is carried out in reverse sequence; note the following:
page 76 .
Specified torques

24 – Mixture preparation - injection

1 Injection system
⇒ o1.1 f fitting locations - injection system”, page 376
1.1 Overview of fitting locations - injection

system
♦ Fitting location overview - engine compartment ⇒ page 376
♦ Overview of fitting locations - left of engine ⇒ page 377
♦ Overview of fitting locations - rear of engine ⇒ page 379
♦ Overview of fitting locations - right of engine ⇒ page 379
♦ Overview of fitting locations - top of engine,
DNPA,DNFC,DNFE,DNFG, DSFE, DRNA ⇒ page 380
♦ Overview of fitting locations - top of engine, DNNA ⇒ page
382
Overview of fitting locations - engine compartment
376 Rep. gr.24 - Mixture preparation - injection

1 - Exhaust gas temperature

sender 3 -G495-
page 486
sender 4 -G648-
page 486
3 - Brake pedal position send‐
er -G100-/brake pedal posi‐
tion sender 2 -G836-
❑ Integrated in brake ser‐
vo -NX6-
❑ The components can‐
not be replaced sepa‐
rately.
❑ Assembly overview
⇒ Brake system; Rep.
gr. 47; Brake ser‐
vo/brake master cylin‐
der, Assembly overview
- brake servo/brake
master cylinder
4 - Gas pedal module -GX2-
❑ Consisting of
♦ Acceleration pedal position
sender -G79-
♦ Accelerator position send‐
er 2 -G185-
❑ The components can‐
not be replaced sepa‐
rately.
❑ Assembly overview
⇒ Fuel supply; Rep.
gr. 20; Accelerator
mechanism; Assembly overview - accelerator pedal module
5 - Engine control unit -J623-
6 - Radiator outlet coolant temperature sender -G83-
❑ Assembly overview ⇒ o2.4 verview - coolant temperature sender”, page 294
Overview of fitting locations - left of engine
1. Injection system 377

1 - Knock sensor 1 -G61-

o1.1 verview - ignition
system”, page 492
2 - Throttle valve module -
GX3-
❑ Consisting of
♦ Throttle valve module -
J338-
♦ Throttle valve drive for
electronic power control -
G186-
♦ Throttle valve drive angle
sender 1 for electronic
power control -G187-
o5.1 verview – intake
manifold”, page 404
3 - No. 1 cyl. injector -N30-
o3.1 verview - fuel rail
with injectors”, page
387
o3.1 verview - fuel rail
with injectors”, page
387
o3.1 verview - fuel rail with injectors”, page 387
❑ Assembly overview ⇒ o3.1 verview - fuel rail with injectors”, page 387
7 - Hall sender -G40-
❑ Assembly overview ⇒ o1.1 verview - ignition system”, page 492
8 - Intake manifold flap air flow control valve -N316-
❑ Assembly overview ⇒ o5.1 verview – intake manifold”, page 404
9 - Radiator outlet coolant -G62-
❑ Assembly overview ⇒ o2.4 verview - coolant temperature sender”, page 294
10 - Stage 2 oil pressure switch -F446-
❑ Assembly overview ⇒ o4.2 verview - oil pressure switches/oil pressure control”, page 267
11 - Turbocharger air recirculation valve -N249-
❑ DNPA, DNNA, DRNA installed on turbocharger
❑ Assembly overview ⇒ o1.1 verview – turbocharger”, page 337
12 - Engine speed sender -G28-
13 - Coolant valve for gearbox -N488-
❑ Assembly overview ⇒ o2.3 verview – coolant valves”, page 293


❑ Assembly overview ⇒ o2.1 verview – charge air system”, page 357
Overview of fitting locations - rear view of engine

-V50-
o2.2 verview - electric
coolant pump”, page
292
2 - Charge pressure control
module -GX34-
❑ Consisting of
♦ Position sender for charge
pressure positioner -G581-
♦ Charge pressure position‐
er -V465-
o1.1 verview – turbo‐
charger”, page 337
3 - Oil level and oil tempera‐
ture sender -G266-
o1.1 verview - sump/oil
pump”, page 249
Overview of fitting locations - engine (view from right side)

1 - Lambda probe 1 after cat‐

alytic converter -GX7-
❑ Consisting of
Lambda probe after cat‐
alytic converter -G130-
Lambda probe 1 heater

after catalytic converter
-Z29-
o9.1 verview - Lambda
probe”, page 433
2 - Lambda probe 1 before
catalytic converter -GX10-
❑ Consisting of
Lambda probe -G39-
Lambda probe heater -

Z19-
probe”, page 433
3 - Pressure differential send‐
er for particulate filter -G1037-
❑ For country versions
with particulate filter
probe”, page 433
4 - Exhaust camshaft control
valve 1 -N318-
o2.1 verview - cover for Volkswagen Technical Site: https://vwts.ru
timing chain”, page 157
5 - Inlet camshaft control valve 1 -N205-
❑ Assembly overview ⇒ o2.1 verview - cover for timing chain”, page 157
6 - Oil pressure switch -F22-
7 - Oil pressure switch for reduced oil pressure -F378-
8 - Valve for oil pressure control -N428-
Overview of fitting locations - top of engine,

DNPA,DNFC,DNFE,DNFG, DRNA, DSFE

1 - Piston cooling jet control

valve -N522-
o4.2 verview - oil pres‐
sure switches/oil pres‐
sure control”, page 267
2 - Intake manifold flap poten‐
tiometer -G336-
3 - Activated charcoal filter
solenoid valve 1 -N80-
❑ Connection diagram
gr. 20; Activated char‐
coal filter system; Con‐
nection diagram - ac‐
tivated charcoal filter
system
4 - Ignition coil 1 -N70-
system”, page 492
5 - Actuator 1 for camshaft
adjustment -F366- (for no. 1
cyl.)
o4.1 verview – valve
gear”, page 207
cyl.)
gear”, page 207
7 - Actuator 3 for camshaft adjustment -F368- (for no. 2 cyl.)
❑ Assembly overview ⇒ o4.1 verview – valve gear”, page 207
13 - Hall sender 2 -G163-
14 - Fuel pressure regulating valve or fuel metering valve
❑ Depending on manufacturer of high-pressure pump:
♦ Fuel pressure regulating valve -N276- or

♦ Fuel metering valve -N290-

❑ Integrated in high-pressure pump, cannot be renewed individually
17 - Intake manifold pressure sender -G71-
Overview of fitting locations - top of engine, DNNA

1 - Piston cooling jet control

valve -N522-
o4.2 verview - oil pres‐
sure switches/oil pres‐
sure control”, page 267
2 - Intake manifold flap poten‐
tiometer -G336-
cyl.)
gear”, page 207
4 - Activated charcoal filter
solenoid valve 1 -N80-
❑ Connection diagram
gr. 20; Activated char‐
coal filter system; Con‐
nection diagram - ac‐
tivated charcoal filter
system
system”, page 492
system”, page 492
10 - High-pressure pump
❑ Depending on manufacturer of high-pressure pump with:
♦ Fuel pressure regulating valve -N276- or



2 Vacuum system
⇒ d2.1 iagram – vacuum system”, page 385
⇒ v2.2 acuum system”, page 385
2.1 Connection diagram – vacuum system
1 - Intake manifold flap air

flow control valve -N316-
2 - Vacuum hose
3 - Intake manifold
❑ With vacuum actuator
for intake manifold flap
4 - Vacuum pump
o8.1 verview - high-
pressure pump”, page
427
5 - Union
6 - Vacuum line
7 - Vacuum hose
❑ To air filter housing
2.2 Checking vacuum system

2. Vacuum system 385

Procedure
– Check all vacuum lines throughout entire vacuum system
for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid
valve to relevant component.
– If entry is stored in event memory, check vacuum lines lead‐
ing to corresponding component and also check other vac‐
uum lines.
– If pressure cannot be built-up using hand vacuum pump
-VAS 6213- or pressure immediately drops again, check
hand vacuum pump and connecting hoses for leaks.

3 Injectors
⇒ o3.1 verview - fuel rail with injectors”, page 387
⇒ a3.2 nd installing fuel rail”, page 388
⇒ a3.3 nd installing injectors”, page 390
⇒ i3.4 njectors”, page 395
3.1 Assembly overview - fuel rail with injectors
1 - Bolt
❑ 20 Nm + 90°
2 - Fuel distributor
fuel rail”, page 388
3 - Fuel pressure sender -
G247-
❑ Lubricate taper lightly
with clean engine oil;
do not lubricate thread
ling fuel pressure send‐
erG247”, page 419
❑ 27 Nm
4 - High-pressure pipe
o8.1 verview - high-
pressure pump”, page
427
5 - Union
❑ Integrated in fuel rail
⇒ Item 2 (page 387) ,
cannot be renewed in‐
dividually
6 - Support ring
7 - O-ring
8 - Spacer ring
9 - Injection valve
❑ Different versions; for allocation refer to ⇒ Electronic parts catalogue
❑ Ensure correct installation position
❑ Removing and installing ⇒ a3.3 nd installing injectors”, page 390
❑ Cleaning ⇒ i3.4 njectors”, page 395
10 - Combustion chamber seal
❑ Renew after removing injector ⇒ a3.3 nd installing injectors”, page 390
3. Injectors 387
3.2 Removing and installing fuel rail

♦ Assembly lever, commercially available

♦ Safety goggles
Removing
fold”, page 406 .
– Place a cloth underneath to catch escaping fuel.
CAUTION
– Unscrew union nuts -1, 2- and remove high-pressure pipe.


1- For injector cylinder 1 -N30-

2- For fuel pressure sender -G247-.
– Unclip wiring holder -3-.
– Remove bolts -arrows- and pull off fuel rail -4- from injectors.
Installing
• Renew spacer rings, O-rings and support rings for injectors
after removal.
• If an injector was released from its seat in the cylinder head,
the combustion chamber seal must be renewed.
after each removal.
– Bring fuel rail -1- into installation position and screw in bolts
-2-.
– Counterhold fuel rail with assembly lever -arrow- and tighten

bolts.
• Distance -a- must be the same all around for all injectors.
– Install high-pressure pipe ⇒ a8.3 nd installing high-pressure
pipe”, page 432 .
page 406 .
3. Injectors 389
Specified torques
♦ ⇒ o3.1 verview - fuel rail with injectors”, page 387
3.3 Removing and installing injectors

♦ Tool set -T10133C-
♦ Tool set -T40433-, not shown

♦ Safety goggles
Removing
• Do not remove injectors unless engine is cold.
– Before removing injectors, thoroughly clean area around
them and blow out with compressed air if necessary. Wear
protective goggles when doing this.
– Removing fuel rail ⇒ a3.2 nd installing fuel rail”, page 388 .
– Pull out injectors from cylinder head.
For stubborn injectors, proceed as follows:
– Cylinder 1: remove piston cooling jet control valve -N522- ⇒
a4.5 nd installing piston cooling jet control valveN522”, page
272 .
– Cover open intake ports with a clean cloth.
– Remove support ring -5- from injector -2-.

• Use a torque wrench to pull out the injector.

• Set the torque wrench to 5 Nm.
• If the torque limit is exceeded, the injector may become
damaged.
– Bosch injector: insert hook -T40433/1- -item 2- in groove on
injector.
– Continental injector: insert hook -T40433/2- -item 2- in

groove on injector.
– Mount removal tool -T10133/16A-.
– Turn bolt -1- with torque wrench to pull out injector.
– If torque limit of »5 Nm« has been reached and injector still
cannot be pulled out, remove puller and use impact sleeve
again to release injector.
– Repeat the procedure on each injector.
Dismantling injector
– Pull off O-ring -4- and spacer ring -3- from injector -2-.
– Carefully remove old combustion chamber ring seal -1-. To
do so, cut open combustion chamber ring using knife or
prise open ring with small screwdriver and then pull off for‐
wards.
5 - Support ring
3. Injectors 391
– Clean groove for seal -arrow-. Remove any (soot) deposits

with a brass wire brush.
• Take care not to damage the groove of injector. The injector

must be renewed if the groove is damaged.
Installing
• Use the entire repair kit when installing.
• Renew support ring after removal.
• Renew combustion chamber seal before reinstalling the in‐
jector.
– Clean bore in cylinder head with brush -T10133/4- -item A-.
– When reinstalling the injector, remove any combustion resi‐

dues from groove for combustion chamber seal and from
injector shaft using a clean cloth.
Installing combustion chamber seal (Bosch injector)
– Push calibrating tool -T40433/5- on injector -1-.

• Observe direction of arrow.

– Place mandrel -T40433/3- with new combustion chamber

seal -2- on injector.
– Push combustion chamber seal into groove for seal using
press tool -T40433/4-.
– Remove mandrel -T40433/3- and press tool -T40433/4- from
injector.
The combustion chamber ring seal is widened when it is pushed
onto the injector. It must be compressed again after sliding on.
This is done as described below.
– Slowly pull off calibrating tool -T40433/5- from injector -1-

with a slight turning motion (about 180°).
Installing combustion chamber seal (Continental injector)
– Place mandrel -T40433/3- with new combustion chamber

seal -2- on injector -1-.
– Push combustion chamber seal into first groove for seal us‐
ing press tool -T40433/4-.
– Remove mandrel -T40433/3- and press tool -T40433/4- from
injector.
The combustion chamber ring seal is widened when it is pushed
onto the injector. It must be compressed again after sliding on.
This is done as described below.
3. Injectors 393
– Slowly push calibrating tool -T40433/5- to stop onto injector

-1- with a slight turning motion (approx. 180°).
• Observe direction of arrow.
– Pull off calibrating tool -T40433/5- again, turning in opposite
direction.
Continued for all:
– Before installing injector -2- moisten new O-ring -4- with

clean engine oil.
• The combustion chamber seal -1- must not be lubricated.
– Push injector into cylinder head bore (free of oil and grease)
as far as it will go by hand. Ensure injectors are positioned
correctly -arrow- in cylinder head.

• Lug -1- and hole -arrow- in cylinder head must face each
other.
• It should be possible to insert the injector easily. If not, wait
until the combustion chamber ring seal has contracted suffi‐
ciently.
– Fit support ring onto injector.
– If removed, install piston cooling jet control valve -N522- ⇒
a4.5 nd installing piston cooling jet control valveN522”, page
272 .
– Installing fuel rail ⇒ a3.2 nd installing fuel rail”, page 388 .
3.4 Cleaning injectors

♦ Ultrasonic cleaning unit -VAS 6418-
♦ Mounting plate for injection modules -VAS 6418/1-
♦ Cleaning fluid -VAS 6418/2-
Cleaning
– Close drain tap -arrow- on ultrasonic cleaning unit -VAS
6418- at right-hand side of housing.
– Fill ultrasonic cleaning device.

Mixing ratio for cleaning fluid:
• 2100 ml of water which was allowed to stand for a while and
20 ml of cleaning fluid -VAS 6418/2-.
– Remove injectors ⇒ a3.3 nd installing injectors”, page 390 .
– Fit mounting plate for injection modules -VAS 6418/1- onto
cleaning unit.
3. Injectors 395
• Before starting ultrasonic cleaning unit -VAS 6418-, it is im‐

portant to note the safety information described in the oper‐
ating manual.
• The ideal fluid level is reached when the cleaning agent is
approx. 1 … 4 mm above the base of the mounting plate.
The ultrasonic cleaner -VAS 6418- could become damaged
if the fluid level is too low.
– Insert injectors into guides of mounting plate for injection
modules -VAS 6418/1- as far as stop.
– Switch on cleaning unit by pressing on/off button -C-.
– Use rotary knob -A- to set cleaning time to 30 minutes.

– Set rotary knob -B- to a temperature of 50°C.
– Press button ► -D- to start the cleaning process.
• Temperature-controlled cleaning is now activated. During
the warm-up period, ultrasonic waves are activated to mix
the cleaning fluid. Once the preselected temperature is
reached, the ultrasonic waves are switched to continuous
operation.
• The cleaning time must be at least 30 minutes and cleaning
only starts at a temperature of at least 50°C.
– Install injectors with new combustion chamber seal ⇒
a3.3 nd installing injectors”, page 390 .

4 Air filter
⇒ o4.1 verview – air filter housing”, page 397
⇒ a4.2 nd installing air filter housing”, page 399
⇒ a4.3 nd installing air guide on lock carrier”, page 401
4.1 Assembly overview – air filter housing

⇒ o4.1.1 verview – air filter housing, Golf, Tiguan, Arteon, T-
Roc, Passat”, page 397
⇒ o4.1.2 verview - air filter housing, Polo”, page 398
4.1.1 Assembly overview – air filter housing, Golf, Tiguan, Arteon, T-Roc, Pas‐
sat
4. Air filter 397

1 - Air duct
❑ On air cleaner (bottom
section)
2 - Air duct (bottom section)
❑ Remove air duct on
lock carrier ⇒ a4.3 nd
installing air guide on
lock carrier”, page 401 .
3 - Bolt
❑ 2 Nm
4 - Air duct (top section)
❑ On lock carrier
5 - Cover
❑ For air duct
6 - Bolt
❑ 1.5 Nm
7 - Breather hose
8 - Not installed
9 - Not installed
10 - Air filter upper part
❑ Remove dirt, leaves
and salt residues
12 - Bolt
❑ 1.5 Nm
13 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals refer to ⇒ Maintenance tables
14 - Application
❑ For air filter lower part
15 - Air filter housing
❑ Remove dirt, leaves and salt residues
17 - O-ring
18 - Water drain hose
❑ With valve
❑ Clean
4.1.2 Assembly overview - air filter housing, Polo

1 - Air filter upper part

and salt residues
2 - O-ring
3 - Air mass meter -G70-
❑ Not fitted
4 - Spring-type clip
5 - Air intake hose
6 - Screw-type clamp
❑ 3 Nm
7 - Bolt
❑ 2 Nm
8 - Air filter element
❑ Use only genuine air
filter elements ⇒ Elec‐
tronic Parts Catalogue
❑ For change intervals re‐
fer to ⇒ Maintenance
tables
ling ⇒ Maintenance;
Booklet
9 - Snow screen
10 - Air filter lower part
and salt residues
12 - O-ring
13 - Water drain hose
❑ With valve
❑ Clean
14 - Air duct
❑ On air cleaner (bottom section)
15 - Air duct
❑ On lock carrier
16 - Bolts
❑ 1.5 Nm
17 - Breather hose
❑ From intake manifold flap valve -N316-
4.2 Removing and installing air filter hous‐

ing
Removing
– Pull off vacuum hose -1-, ensuring that it is not damaged
when doing so.
4. Air filter 399

– Release hose clip -2- and detach air intake hose.

– Pull off air filter housing -3- from battery tray.
– If fitted, release fasteners -arrows-, and disconnect air intake
hose.
– Turn air filter housing -2- in -direction of arrow- out of front
air duct -c-.
Installing
• A clean air filter housing is essential.
• If necessary, use soapy water to fit air hoses.
– Disconnect water drain hose -arrow-.
– Clean debris from connection on lower part of air filter and

hose.
• Water drain hose must be routed downwards without kinks.

– Fit air filter housing on battery tray and press on so that it

engages audibly.
Specified torques
4.3 Removing and installing air guide on

lock carrier
⇒ a4.3.1 ir duct on lock carrier, Golf, Tiguan, Arteon, Passat”,
page 401
⇒ a4.3.2 ir guide on lock carrier, T-Roc”, page 402
⇒ a4.3.3 ir guide on lock carrier, Polo”, page 403
4.3.1 Removing air duct on lock carrier, Golf,

Tiguan, Arteon, Passat
Removing

– Release catch -arrow- and remove cover -2-.
– Release fasteners -arrows- and detach air duct (top section)

-1-.
– Unscrew bolt -arrow- on left and right.
4. Air filter 401

– Unclip lower part of air duct -1- and remove it.

Installing
– Install in reverse order of removal.
4.3.2 Removing air guide on lock carrier, T-

Roc
Removing
– Remove radiator grille ⇒ General body repairs, exterior;
Rep. gr. 63; Front bumper; Assembly overview - bumper
cover.
– Unscrew bolts -3- from cover -1-.
– Open rear fastener -2-.

– Release front fastener -arrow- and remove cover -1-.

– Release fastener -arrows- and remove air guide -1- up‐

wards.
– Unscrew bolts -arrows- and remove bottom part of air guide
-1-.
Installing
– Install in reverse order of removal.
4.3.3 Removing air guide on lock carrier, Po‐

lo

– Unclip air duct -2-, and remove it.
4. Air filter 403

5 Intake manifold
⇒ o5.1 verview – intake manifold”, page 404
⇒ a5.2 nd installing intake manifold”, page 406
⇒ a5.3 nd installing throttle valve moduleGX3”, page 410
⇒ t5.4 hrottle valve moduleGX3”, page 411
⇒ a5.5 nd installing intake manifold flap valveN316”, page 412
⇒ i5.6 ntake manifold change-over”, page 412
5.1 Assembly overview – intake manifold

1 - Bolt
❑ Thread-cutting
❑ Fit and screw in bolt
by hand to ensure it
is screwed into old
thread. Then tighten
bolt to specified torque.
❑ 7 Nm
2 - Throttle valve module -
GX3-
❑ with
♦ Throttle valve module -
J338-
♦ Throttle valve drive for
electronic power control -
G186-
ling throttle valve mod‐
uleGX3”, page 410
❑ Cleaning ⇒ t5.4 hrot‐
tle valve moduleGX3”,
page 411
6
3 - Seal
4 - Intake manifold flap potentiometer -G336-
5 - O-ring
6 - Intake manifold
❑ Removing and installing ⇒ a5.2 nd installing intake manifold”, page 406
7 - Seal
8 - Bolt
❑ Specified torque and tightening sequence ⇒ Fig. ““Intake manifold - specified torque and tightening
9 - Ball stud
❑ 9 Nm
10 - O-ring
5. Intake manifold 405

❑ Removing and installing ⇒ a6.3 nd installing intake manifold senderGX9”, page 419
12 - Bolt
❑ Thread-cutting
torque.
❑ 1.5 Nm
13 - Ball stud
❑ 9 Nm
14 - Intake manifold flap air flow control valve -N316-
❑ Removing and installing ⇒ a5.5 nd installing intake manifold flap valveN316”, page 412
15 - Vacuum hose
16 - Vacuum hose
❑ From vacuum pump
17 - Vacuum hose
18 - Retainer
❑ For electrical connectors
19 - Bolt
❑ Thread-cutting
torque.
❑ 5 Nm
Intake manifold - specified torque and tightening sequence
– Tighten bolts -1 to 10- to 8 Nm in the sequence shown.
5.2 Removing and installing intake mani‐

fold

Removing
ing”, page 399 .
– Unclip lower part of intake air duct -1- and remove.

– Free off wiring harness from clip -1-.
– Release fasteners -arrows- and detach wiring duct -3- from

bracket.
– Unscrew bolts -1- for upper coolant pipe.

– Unscrew bolts -arrows- for front coolant pipe.
– Separate electrical connectors and free off electrical wiring:
1 - For intake manifold flap potentiometer -G336-.

3 - For intake manifold sender -G71-.
4 - For throttle valve module -GX3-
– Free off fuel hose -2- and push to one side.
– Disconnect connector -1- for intake manifold flap valve -
N316-.

– Disconnect vacuum hose -2-, ensuring that it is not damaged

when doing so.
them.
– Unscrew bolts -1 to 10- and remove intake manifold.
– Seal open channels of intake system with clean cloths or

with thoroughly cleaned plugs from engine bung set -VAS
6122-.
Installing
– Install oil filter element ⇒ o1.2 il:”, page 252 .
page 399 .

Specified torques
♦ ⇒ Fig. ““Intake manifold - specified torque and tightening
5.3 Removing and installing throttle valve

module -GX3-
Removing
– Remove air intake pipe between throttle valve module and
charge air cooler.
♦ ⇒ a2.6.1 nd installing air intake pipe for throttle valve mod‐
DSFF”, page 368
♦ ⇒ a2.6.2 nd installing air intake pipe for throttle valve mod‐
ule/charge air cooler, DNPA, DNNA, DNND, DRNA ”, page
370
– Unscrew bolts -arrows- and push front coolant pipe to one
side slightly.
– Unscrew bolts -arrows- and remove throttle valve module

-GX3-.
Installing
– Install in reverse order of removal, observing the following:

– Clean sealing surface for O-ring.

– Install front air intake pipe ⇒ a2.6.1 nd installing air intake
pipe for throttle valve module/charge air cooler, DNFC,
Adjustments must be made after renewing throttle valve module
⇒ d3.2 iagnoses”, page 6 .
Specified torques
5.4 Cleaning throttle valve module -GX3-

♦ Acetone (commercially available)
♦ Brush
♦ Safety goggles
Procedure
• Contamination and coking in end stop can result in incorrect
adaptation values.
• When cleaning the throttle valve housing, take care not to
scratch it.
– Remove throttle valve module -GX3- ⇒ a5.3 nd installing
throttle valve moduleGX3”, page 410 .
– Open throttle valve by hand and lock it in open position with
a wedge (plastic or wood) -arrow-.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and may cause eye and skin irritation.
– Clean throttle valve housing thoroughly, especially around

the points -arrows- where the throttle valve closes, using
commercially available acetone and a small brush.

– Wipe the inside of the throttle valve housing with a lint-free

cloth.
– Allow acetone to dry off completely.
– Install throttle valve module -GX3- ⇒ a5.3 nd installing throt‐
tle valve moduleGX3”, page 410 .

fold flap valve -N316-
Removing
• Intake manifold removed ⇒ a5.2 nd installing intake mani‐
fold”, page 406 .
– Pull off vacuum hose -2- and free off vacuum line -1-.
– Release fasteners -arrows - and pull off intake manifold flap

valve -N316- -item 3-.
Installing
5.6 Checking intake manifold change-over

Perform check only if there is a loss of torque. This means
when there is a lack of elasticity or a lack of pulling power.

Check condition
• The intake manifold flap valve -N316- was checked with a
vehicle diagnostic tester.
If the intake manifold flap valve -N316- is OK, perform the fol‐
lowing tests:
er”, page 76 .
– Start engine and run it at idling speed.
– Have a second person abruptly increase engine speed
(throttle burst). Observe vacuum unit for intake manifold
changeover.
• The rod assembly -1- of actuator for intake manifold flap
must pull -arrow-.
If changeover does not operate as indicated:

– Check vacuum system for leaks.
– Check that vacuum lines are connected correctly.
– Check vacuum hoses for porosity.
– Move slide ring -1- on hand vacuum pump -VAS 6213-
-item 2- to position -A- for "vacuum".

– Connect hand vacuum pump -VAS 6213- to actuator for

intake manifold flap valve -N316-.
– Operate hand vacuum pump -VAS 6213- several times.

• The rod assembly -1- of actuator for intake manifold flap
must pull.
– Reduce vacuum.
• The rod assembly returns to its initial position.
• The rod assembly has to move in both directions -arrows-.
– If the rod assembly does not move, renew intake manifold.

6 Senders and sensors

⇒ o6.1 verview - actuator for structure-borne sound and control
unit for structure-borne sound”, page 415
⇒ u6.2 nit for structure-borne soundJ869 and actuator for struc‐
ture-borne soundR214”, page 418
⇒ a6.3 nd installing intake manifold senderGX9”, page 419
⇒ a6.4 nd installing fuel pressure senderG247”, page 419
⇒ f6.5 uel pressure senderG247”, page 420
⇒ a6.6 nd installing pressure differential sender for particulate
filterG1037”, page 423
6.1 Assembly overview - actuator for struc‐

ture-borne sound and control unit for
structure-borne sound
⇒ o6.1.1 verview - actuator for structure-borne sound and con‐
trol unit for structure-borne sound”, page 415
⇒ o6.1.2 verview - actuator for structure-borne sound and con‐
trol unit for structure-borne sound, Polo”, page 416
6.1.1 Assembly overview - actuator for structure-borne sound and control unit
for structure-borne sound
6. Senders and sensors 415

1 - Support
❑ for control unit for
structure-borne sound -
J869-
2 - Control unit for structure-
borne sound -J869-
ling ⇒ page 418
3 - Electrical connector
4 - Nut
❑ 5 Nm
5 - Actuator for structure-
borne sound -R214-
ling ⇒ page 418
6 - Electrical connector
6.1.2 Assembly overview - actuator for structure-borne sound and control unit
for structure-borne sound, Polo

1 - Actuator for structure-

borne sound -R214-
❑ Fitting location: in ple‐
num chamber
❑ To remove or install,
remove plenum cham‐
ber bulkhead ⇒ Gener‐
al body repairs, exteri‐
or; Rep. gr. 50; Plenum
chamber bulkhead; Re‐
moving and installing
plenum chamber bulk‐
head.
❑ Attached to bracket
with nut, item -2-
2 - Nut
❑ for actuator for struc‐
ture-borne sound -
R214-
❑ Loosen and tighten us‐
ing roughened open-
end spanner
❑ 7 Nm
3 - Bracket
❑ for actuator for struc‐
ture-borne sound -
R214-
❑ Can only be renewed
with windscreen re‐
moved
4 - Bolts
❑ Can only be unscrewed
with windscreen re‐
moved
❑ 9 Nm
5 - Control unit for structure-borne sound -J869-
❑ Fitting location: in plenum chamber
❑ Remove plenum chamber for removing ⇒ General body repairs, exterior; Rep. gr. 50; Plenum cham‐
ber bulkhead; Removing and installing plenum chamber cover.
❑ Secured by threaded fasteners or clips depending on version
6 - Connector
❑ for control unit for structure-borne sound -J869-
7 - Support
❑ for control unit for structure-borne sound -J869-
❑ May vary slightly depending on version
8 - Support
❑ for actuator for structure-borne sound -R214-
❑ May vary slightly depending on version
9 - Connector
❑ for actuator for structure-borne sound -R214-

6.2 Control unit for structure-borne sound

-J869- and actuator for structure-borne
sound -R214-
Removing
– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Plenum chamber bulkhead; Removing
and installing plenum chamber cover.
Control unit for structure-borne sound -J869-:

– Release fastener -arrow A-, remove control unit for struc‐
ture-borne sound -J869- from bracket -arrow B-.
Actuator for structure-borne sound -R214-:
– Unscrew nut -arrow-.

– Remove actuator for structure-borne sound -R214- and sep‐
arate electrical connector -1-.
Installing
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50; Plenum chamber bulkhead; Removing and
installing plenum chamber cover.
Specified torques
♦ ⇒ o6.1 verview - actuator for structure-borne sound and con‐
trol unit for structure-borne sound”, page 415


fold sender -GX9-
Removing
er”, page 76 .

– Release fasteners -arrows-, and pull intake manifold pres‐
sure sender -G71- off intake manifold.
Installing
page 76 .
Specified torques
6.4 Removing and installing fuel pressure

sender -G247-
♦ Socket -T40363- (not shown)

♦ Safety goggles

Removing
er”, page 76 .
– Unscrew bolts -arrows- and push front coolant pipe to one
side slightly.
– Release connector -arrow- using assembly tool -T10118-.
CAUTION
– Unscrew fuel pressure sender -G247-.

Installing
Specified torques
6.5 Checking fuel pressure sender -G247-


♦ Test instrument adapter/DSO (2+3-pin) -VAS 5571-
♦ Pressure sensor tester -VAS 6394-
♦ Safety goggles
Procedure
– Remove fuel pressure sender -G247- ⇒ a6.4 nd installing
fuel pressure senderG247”, page 419 .
– Screw in adapter -VAS 6394/3- in place of fuel pressure
sender -G247-, and tighten it to 27 Nm.
– Unscrew plug on digital pressure gauge and tighten fuel

pressure sender -G247- -item 2- in its place to specified
torque.
– Connect vehicle and fuel pressure sender -G247- electrically
using test instrument adapter/DSO (2+3-pin) -VAS 5571-.
– Switch on ignition and select the following function ⇒ Vehicle
diagnostic tester:
♦ Diagnosis-capable systems

♦ 0001 - Engine electronics, functions

♦ 0001 - Measured values
♦ Fuel pressure
• Display field shows the actual value reported to the engine
control unit by the fuel pressure sender -G247-.
– Switch on digital pressure gauge -VAS 6394/1- by pressing
button -A- once briefly.
• Display on -VAS 6394/1- should read 0 bar.

– If display is different, press button -C- once briefly to initiate
zero balance.
– Connect pressure line of digital pressure gauge -VAS
6394/1- -item 1- on adapter -VAS 6394/3- and tighten.
– Start the engine.

– Compare pressure displayed on -VAS 6394/1- with actual
value displayed on vehicle diagnostic tester.
• A maximum pressure deviation of 5 bar is permissible.
– If deviation is greater than 5 bar, try a new fuel pressure
sender -G247-.
CAUTION

– Screw new fuel pressure sender -G247- into digital pressure

gauge -VAS 6394/1-.
– Repeat the test with the new fuel pressure sender -G247-
and compare both measured values.
– If measured values are again different, check electrical con‐
nection between fuel pressure sender -G247- and engine
control unit ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Once measured values match, install new fuel pressure
sender -G247- ⇒ a6.4 nd installing fuel pressure send‐
erG247”, page 419 .
Specified torques
6.6 Removing and installing pressure dif‐

ferential sender for particulate filter -
G1037-
Removing
• Fit all heat shield sleeves in the same place when installing.
er”, page 76 .
– Open heat insulation sleeve.

– Spray hoses -3- on pressure differential sender for particu‐
late filter -G1037- with soapy water.

– To prevent connections from breaking off, pull off hoses

carefully and in a straight line from the connections.
Installing
• To clear blockages or ice formation from condensation, blow
through hose in direction of catalytic converter with particu‐
late filter using compressed air.
• Make sure that hoses are securely fitted and seal properly.
• If the control lines on the catalytic converter with particulate
filter were loosened, tighten them to the specified torque.
page 76 .
Specified torques

7 Engine control unit

⇒ a7.1 nd installing engine control unitJ623”, page 425
7.1 Removing and installing engine control

unit -J623-
Removing
• If engine control unit is to be renewed, select Renew engine
control unit on ⇒ Vehicle diagnostic tester in Guided
Functions .
– Switch off ignition.
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
– Release fastener -arrow A-, and remove engine control unit
-J623- -arrow B-.
– Release and pull off connectors for engine (motor) control

unit -J623-.
Installing
7. Engine control unit 425

– Insert lower edge of engine control unit -J623- into bracket

-arrow A-, and engage engine control unit in bracket at up‐
per edge.
• When doing this, ensure that lugs of engine control unit en‐
gage in notches at top and bottom of bracket -arrows B-.
– Install battery ⇒ Electrical system; Rep. gr. 27; Battery; Re‐
moving and installing battery.
After a new engine (motor) control unit has been installed, the
following work procedure must be carried out:
– Activate engine control unit ⇒ Vehicle diagnostic tester Gui-
ded Functions , Renewing engine control unit .

8 High-pressure pump
⇒ o8.1 verview - high-pressure pump”, page 427
⇒ a8.2 nd installing high-pressure pump”, page 430
⇒ a8.3 nd installing high-pressure pipe”, page 432
8.1 Assembly overview - high-pressure pump
8. High-pressure pump 427

1 - High-pressure pipe
❑ To loosen union nut,
counterhold on hexa‐
gon of connection with
an open-end spanner.
❑ Do not alter shape.
❑ Install free of tension.
❑ Coat ball of high-pres‐
sure pipe and thread of
union nut with clean en‐
gine oil.
high-pressure pump”,
page 430
tightening sequence
⇒ Fig. ““High-pressure
pipe - specified tor‐
que and tightening se‐
2 - Union
❑ For high-pressure pipe
❑ Renew if leaking
❑ To loosen union nut
on high-pressure pipe,
counterhold on hexa‐
gon of connection with
an open-end spanner.
❑ Renew if loosened
❑ 60 Nm
3 - Fuel supply hose
❑ From fuel tank
4 - Bolt
❑ Specified torque and tightening sequence ⇒ Fig. ““High-pressure pump - specified torque and tighten‐
5 - Seal
❑ Renew
6 - Connection piece
7 - Vacuum hose
8 - O-ring
9 - Vacuum pump
❑ Vacuum pump is driven mechanically
❑ Testing vacuum system ⇒ v2.2 acuum system”, page 385
❑ Removing and installing ⇒ a1.3 nd installing vacuum pump”, page 153
10 - Bolt
❑ 9 Nm
11 - O-ring
12 - Roller tappet

❑ Can remain inserted in vacuum pump after removal of high-pressure pump
13 - High-pressure pump
❑ Depending on manufacturer of high-pressure pump with:
♦ Fuel pressure regulating valve -N276-
Or
❑ Removing and installing ⇒ a8.2 nd installing high-pressure pump”, page 430
❑ Keep straight when installing.
High-pressure pump - specified torque and tightening sequence
To prevent flange of high-pressure pump from being deformed

during installation, fit high-pressure pump as follows:
– Tighten bolts -arrows- in stages as follows:
2 Tighten one turn alternately until flange of high-
pressure pump makes contact with vacuum pump
3 25 Nm
High-pressure pipe - specified torque and tightening sequence
Mount high-pressure pipe free of stress:

– Tighten union nuts in stages as follows:
Stage Union nuts Specified torques
1 -1, 2- Screw in by hand as far as stop
2 -1- 40 Nm

Stage Union nuts Specified torques

3 -2- 40 Nm
8.2 Removing and installing high-pressure

pump
♦ Safety goggles
Removing
• High-pressure pump may only be removed when the engine
is cold.
– Remove high-pressure pipe ⇒ a8.3 nd installing high-pres‐
sure pipe”, page 432 .

CAUTION

– Press release buttons and remove fuel hose -2-.
– If subsequently cylinder head is to be removed, free off fuel
hose on intake manifold.
– Carefully pull out high-pressure pump.
– If roller tappet remains stuck in vacuum pump, remove roller
tappet.
Installing
• Moisten roller tappet and O-ring with clean engine oil when
installing.
– Check roller tappet for damage and renew if necessary.
– Insert roller tappet in vacuum pump, paying attention to lo‐
cating element -arrows A, B- when doing so.
NOTICE
– Turn crankshaft on nut of alternator pulley in direction of en‐

gine rotation until roller tappet in vacuum pump has reached
lowest point.
– Insert high-pressure pump with O-ring in vacuum pump and
tighten bolts in stages.
– Install high-pressure pipe ⇒ a8.3 nd installing high-pressure
pipe”, page 432 .
– Check fuel system for leaks.

Specified torques
♦ ⇒ Fig. ““High-pressure pump - specified torque and tighten‐
8.3 Removing and installing high-pressure

pipe
♦ Socket -T40434-
Removing
er”, page 76 .
371 .
– Unscrew union nuts -1, 2- and remove high-pressure pipe.

Installing
– Check fuel system for leaks.
page 76 .
Specified torques
♦ ⇒ Fig. ““High-pressure pipe - specified torque and tightening

9 Lambda probe
⇒ o9.1 verview - Lambda probe”, page 433
⇒ a9.2 nd installing Lambda probe”, page 435
9.1 Assembly overview - Lambda probe
9. Lambda probe 433


sender 4 -G648-
❑ ⇒ o3.1 verview – ex‐
haust gas temperature
regulation”, page 486
2 - Dual exhaust gas temper‐
ature sensor 1 -GX41-
3 - Nut
❑ 9 Nm
sender 3 -G495-
Lambda probe”, page
435
❑ Installation instructions
⇒ page 436
❑ 60 Nm
Lambda probe”, page
435
❑ Installation instructions
⇒ page 436
❑ 60 Nm
7 - Bolt
❑ 9 Nm
8 - Pressure differential sender for particulate filter -G1037-
Removing and installing ⇒ a6.6 nd installing pressure differential sender for particulate filterG1037”, page
423
9 - Retainer
❑ With control lines
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Bracket
❑ For control lines
13 - Union nut
❑ For control line
❑ 45 Nm

14 - Union nut
❑ For control line
❑ 45 Nm
9.2 Removing and installing Lambda probe

♦ Lambda probe open ring spanner set -3337-
Removing
er”, page 76 .
Lambda probe 1 before catalytic converter -GX10-:
– Detach electrical connector -2- from bracket, disconnect and

free off electrical wire.
– Unscrew Lambda probe 1 before catalytic converter -GX10-
-item 1- using tool from Lambda probe open ring spanner set
-3337-.
Lambda probe 1 after catalytic converter -GX7-:
9. Lambda probe 435

– Detach electrical connector -arrow- from bracket, disconnect

and free off electrical wire.
– Unscrew lambda probe 1 after catalytic converter -GX7-
-arrow- using a suitable tool from lambda probe open ring
spanner set -3337-.
Installing
• Threads on new Lambda probes are coated with assembly
paste.
• When reusing existing Lambda probe, coat thread with high-
temperature paste ⇒ Electronic parts catalogue.
• Assembly paste or high-temperature paste must not get into
slots in Lambda probe
• During installation, it is essential that wiring of lambda probe
is reattached in same positions. The wire must be prevented
from touching the exhaust pipe.
– Fit engine cover panel ⇒ page 76 .
Specified torques

26 – Exhaust system
1 Exhaust pipes and silencers
⇒ o1.1 verview – silencers”, page 437
⇒ a1.2 nd installing silencer”, page 447
⇒ e1.3 xhaust pipes from silencers”, page 457
⇒ e1.4 xhaust system free of stress”, page 464
⇒ e1.5 xhaust system for leaks”, page 464
⇒ a1.6 nd installing bracket for catalytic converter, Tiguan”,
page 464
1.1 Assembly overview – silencers

⇒ o1.1.1 verview - silencer, Golf, front-wheel drive”, page 437
⇒ o1.1.2 verview - silencer, Golf, all-wheel drive”, page 439
⇒ o1.1.3 verview - silencers, Golf R”, page 440
⇒ o1.1.4 verview - silencers, Tiguan”, page 442
⇒ o1.1.5 verview - silencer, Arteon, Passat”, page 443
⇒ o1.1.6 verview - silencers, T-Roc”, page 445
⇒ o1.1.7 verview - silencers, Polo”, page 445
1.1.1 Assembly overview - silencer, Golf, front-wheel drive
1. Exhaust pipes and silencers 437

1 - Front clamping sleeve

❑ Align exhaust system
free of tension before
tightening ⇒ page 464 .
❑ Tighten bolted connec‐
tions evenly to 30 Nm
2 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
ling ⇒ page 447
❑ Aligning exhaust sys‐
tem free of tension ⇒
page 464 .
3 - Bolt
❑ 20 Nm
4 - Bracket
5 - Retainer
6 - Rear silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
ling ⇒ page 447
page 464 .
7 - Rear clamp
❑ Only for repair work
❑ Align exhaust system free of tension before tightening ⇒ page 464 .
❑ Fitting position ⇒ page 438
❑ Tighten bolted connections evenly to 30 Nm
Installation position of rear clamp
– Fit clamp in position shown.
438 Rep. gr.26 - Exhaust system

• Bolted connections facing to left.

• Bolt -arrow- must not protrude beyond lower edge of clamp.
1.1.2 Assembly overview - silencer, Golf, all-wheel drive
1 - Clamping sleeve
❑ 30 Nm
❑ Fitting position ⇒ page
439
❑ Tighten threaded con‐
nections evenly.
2 - Centre silencer
ling ⇒ page 448
❑ Separating exhaust
pipes from silencers ⇒
page 457
page 464 .
3 - Retainer
4 - Rear right silencer
repair purposes.
❑ Separating point
-arrow-
page 457
5 - Mounting with retaining loop
6 - Bolt
❑ 20 Nm
7 - Rear left silencer
❑ In initial equipment, component with centre silencer. Can be renewed individually for repair purposes.
❑ Separating point -arrow-, only for Passat
❑ Separating exhaust pipes from silencers ⇒ page 457
8 - Mounting with retaining loop
Installation position of clamp


1.1.3 Assembly overview - silencers, Golf “R”

1 - Centre silencer
ling ⇒ page 447
page 464 .
2 - Nuts
❑ Qty. 6
❑ Specified torque ⇒
page 441
3 - Exhaust flap control unit 2
-J945-
ling ⇒ page 485
4 - Retaining rings
❑ Qty. 4
5 - Bracket
❑ Qty. 3
6 - Bolts
❑ Qty. 3
❑ 20 Nm
7 - Rear silencer
ling ⇒ page 447
page 464 .
8 - Exhaust flap control unit
-J883-
ling ⇒ page 485
9 - Nuts
❑ Qty. 2
❑ 20 Nm
10 - Clamping sleeve
❑ Tighten threaded connections evenly.
❑ Aligning exhaust system free of tension ⇒ page 464 .
Exhaust flap control unit – specified torque


– Tighten nuts -4- to 3 Nm.
1.1.4 Assembly overview - silencers, Tiguan
Note
♦ Renew seals and self-locking nuts after they have been re‐
moved.
♦ 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 clamp and align silencers
and exhaust pipe so that sufficient clearance is maintained
to the bodywork at all points and the mountings are evenly
loaded.

1 - Bolt
❑ 25 Nm
2 - Bracket
3 - Mounting
4 - Clamping sleeve
❑ Turn clamp in such a
way that there is suffi‐
cient clearance to adja‐
cent components
5 - Rear silencer
tem free of stress
1.1.5 Assembly overview - silencer, Arteon,

Passat
Note
moved.
loaded.

1 - Front clamping sleeve

cent components.
2 - Centre silencer
ling ⇒ page 447
❑ Cutting point ⇒ page
457
page 464 .
3 - Retainer
4 - Rear clamp
❑ Only for repair work
5 - Rear left silencer
component with centre silencer. Can be renewed individually for repair purposes.
❑ Cutting point ⇒ page 457
6 - Retainer
7 - Bolt
❑ 20 Nm
8 - Rear right silencer
❑ In initial equipment, component with centre silencer. Can be renewed individually for repair purposes.
❑ Cutting point ⇒ page 457
9 - Retainer

1.1.6 Assembly overview - silencers, T-Roc
Note
moved.
loaded.
1 - Bolt
❑ 25 Nm
2 - Bracket
3 - Mounting
4 - Clamping sleeve
cent components
5 - Coupling point
6 - Mounting
7 - Rear silencer and centre
silencer
tem free of stress
1.1.7 Assembly overview - silencers, Polo

1 - Mounting
2 - Bolt
❑ 20 Nm
❑ Qty. 2
3 - Rear silencer
repair purposes.
page 457
page 464 .
4 - Mounting
5 - Centre silencer
page 457
page 464 .
6 - Clamping sleeve
❑ Turn clamp in such a way that there is sufficient clearance to adjacent components.
❑ Tighten bolted connections evenly to 25 Nm
❑ Installation position ⇒ page 446
7 - Mounting
Installation position of clamp


• Turn clamp in such a way that there is sufficient clearance to
adjacent components.
1.2 Removing and installing silencer

⇒ a1.2.1 nd installing silencer, Golf, front-wheel drive”, page
447
⇒ a1.2.2 nd installing silencer, Golf, all-wheel drive”, page 448
⇒ a1.2.3 nd installing silencer, Tiguan”, page 450
⇒ a1.2.4 nd installing silencer, Arteon, Passat”, page 452
⇒ a1.2.5 nd installing silencers, T-Roc”, page 453
⇒ a1.2.6 nd installing front silencer, Polo”, page 454
⇒ a1.2.7 nd installing rear silencer, Polo”, page 456
1.2.1 Removing and installing silencer, Golf,

front-wheel drive
Removing
– Remove rear tunnel cross-piece -2-.
– Loosen bolt connections for front clamp -arrow-.

CAUTION
Risk of accident caused by high weight of silencers.
work.
– Detach exhaust hanger -1-, and unbolt exhaust hanger -2-

from body. Remove silencer.
Installing
– Align exhaust system free of stress ⇒ page 464 .
Specified torques
♦ Underbody cladding; Assembly overview - underbody clad‐
ding ⇒ General body repairs, exterior; Rep. gr. 66; Under‐
body cladding; Overview of fitting locations - underbody
cladding
1.2.2 Removing and installing silencer, Golf,

all-wheel drive
Removing
– If fitted, remove rear left underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66; Underbody cladding; Overview
of fitting locations - underbody cladding.

CAUTION
work.
– Loosen clamp -arrows-, and push it forwards.
Note
♦ Centre silencer as well as both rear silencers are combined

in one unit when fitted in the factory. In the event of repairs,
they need to be renewed individually.
♦ Cut exhaust pipe ⇒ page 457 .
– Unscrew bolt -1-, and place exhaust pipe -2- on tunnel

cross-piece.
– Press rubber mounting -arrow- off exhaust pipe pin -1-.

– If fitted, pull connectors from exhaust flap control units on

right and left off rear silencer.
– Unscrew bolt -2- for rear right silencer -1-.
– Unscrew bolt -2- for rear left silencer -1-.
Installing
Specified torques
♦ ⇒ page 439
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Overview of fitting locations - underbody cladding
1.2.3 Removing and installing silencer, Ti‐

guan
♦ Tensioning strap -T10038-

Removing
CAUTION
work.
– Loosen clamp -arrows- and push to rear.
– Secure exhaust pipe -1- on propshaft with tensioning strap

-2-.
– Unscrew bolts -1- for mounting -2-.
– Remove silencer -3-.

Installing
Specified torques ⇒ page 437
1.2.4 Removing and installing silencer, Ar‐

teon, Passat
CAUTION
work.
– Detach exhaust hanger -1-, and unbolt exhaust hangers

-2, 3 and 4- from body. Remove exhaust system -A-.
Installing
Specified torques
♦ ⇒ o1.1.5 verview - silencer, Arteon, Passat”, page 443


cladding
1.2.5 Removing and installing silencers, T-

Roc
♦ Tensioning strap -T10038-
Removing
CAUTION
work.
– Loosen clamp -arrows-, and push it forwards.
– Secure catalytic converter and exhaust pipe -1- on propshaft

with tensioning strap -2-.

– Detach centre exhaust hanger -arrows-.
– Unscrew bolts -1- for mounting -2-.
– Remove silencer -3-.

Installing
Specified torques
1.2.6 Removing and installing front silencer,

Polo

Removing
– If fitted, remove middle underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66; Underbody cladding; Remov‐
ing and installing underbody cladding.
– Remove rear tunnel cross-piece ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing tunnel cross-piece.
CAUTION
Danger of burning injuries from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool down.
– Loosen nuts -4-.
– Push clamp -3- forwards.

– Disconnect exhaust pipe/rear silencer ⇒ page 457 .
CAUTION
work.
– Disengage retaining ring -1-.

– Remove front silencer -2- with aid of second mechanic.
Installing

– Note installation position of clamp ⇒ page 438

Specified torques
♦ ⇒ o1.1.7 verview - silencers, Polo”, page 445
1.2.7 Removing and installing rear silencer,

Polo
Removing
CAUTION
Danger of burning injuries from hot exhaust system.
Risk of burns to hands and other parts of body.
– Allow exhaust system to cool down.
– Disconnect exhaust pipe/rear silencer ⇒ page 457 .
CAUTION
work.

– Remove rear silencer -2- with aid of second mechanic.

Installing
– Note installation position of clamp ⇒ page 438 .
Specified torques
♦ ⇒ o1.1.7 verview - silencers, Polo”, page 445
1.3 Separating exhaust pipes from silenc‐

ers
⇒ e1.3.1 xhaust pipes/silencers, Golf, front-wheel drive”, page
457
⇒ e1.3.2 xhaust pipes and silencers, Arteon, Passat, Golf all-
wheel drive”, page 458
⇒ e1.3.3 xhaust pipes/silencers, T-Roc”, page 461
⇒ e1.3.4 xhaust pipes/silencers, Polo”, page 462
1.3.1 Separating exhaust pipes/silencers,

Golf, front-wheel drive
♦ The connecting pipe can be cut through at the cutting loca‐
tion in order to renew the centre and rear silencers separate‐
ly.
♦ The separating point is marked with indentations on the out‐
side of the exhaust pipe.
♦ Chain pipe cutter -VAS 6254-
Or
♦ Pneumatic sabre saw -V.A.G 1523B-

Procedure
– Cut through exhaust pipe at right angles at separating point

-arrow- using chain pipe cutter -VAS 6254- or body saw
-VAS 6780-.
– Position clamp centrally at side marks -arrows- when instal‐
ling.
– Install clamping sleeve so that end of bolt -arrow- does not

extend beyond lower edge of clamping sleeve.

– Tighten bolted connections evenly to 30 Nm.
1.3.2 Separating exhaust pipes and silenc‐

ers, Arteon, Passat, Golf all-wheel
drive

Or
♦ The connecting pipe -1- can be cut through at the separating

points in order to renew the rear silencers separately.
♦ For individual renewal of the centre silencer, a cutting point

is provided in the connecting pipe.
♦ The separating point -arrow- is marked with indentations on

the outside of the exhaust pipe.

♦ A second mechanic is required for the procedure.

Separating right rear silencer
– Unscrew bolt -2- for rear right silencer -1-.

– Cut through exhaust pipe -1- at right angles at separating
point -arrow- using chain pipe cutter -VAS 6254- or pneu‐
matic sabre saw -V.A.G 1523B-.
Separating left rear silencer
– Unscrew bolt -2- for rear left silencer -1-.

– Cut through exhaust pipe of rear silencer -1- at right angles
at separating point -arrow- using chain pipe cutter -VAS
6254- or pneumatic sabre saw -V.A.G 1523B-.

Installing rear silencer
– Position clamp -1- centrally at side marks -arrows- when

installing.
– Turn clamp in such a way that there is sufficient clearance to
– Tighten threaded connections evenly. Specified torque ⇒
page 437 .
1.3.3 Separating exhaust pipes/silencers, T-

Roc
Or

– Cut through exhaust pipe of centre silencer at right angles at

separating point -arrow- using chain pipe cutter -VAS 6254-
or body saw -V.A.G 1523B-.
– Position clamp -arrow- centrally relative to side marks when

installing.

– Tighten threaded connections evenly.
Clamping sleeve 25 Nm
1.3.4 Separating exhaust pipes/silencers,

Polo
♦ The connecting pipe can be cut through at the cutting loca‐
tion in order to renew the centre and rear silencers separate‐
ly.
♦ Cutting location is marked by an indentation on the circum‐
ference of exhaust pipe.


♦ or body saw -VAS 6780-

Procedure
– Remove rear left underbody cladding ⇒ General body re‐

pairs, exterior; Rep. gr. 66; Underbody cladding; Overview of
fitting locations - underbody cladding.
– Cut through exhaust pipe at right angles at centre separating
point -upper arrow- using chain pipe cutter -VAS 6780-.
– Position clamp centrally at side marks -arrows- when instal‐
ling.

– Tighten threaded connections evenly.
Clamping sleeve 25 Nm

1.4 Aligning exhaust system free of stress

Procedure
• The exhaust system must be aligned when cold.
– Push exhaust system towards front of vehicle until preload‐

ing at mounting for exhaust pipe -a- = 5 mm.
1.5 Checking exhaust system for leaks

– Start engine and run it at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage test.
– Check (by listening) points of connection between exhaust
manifold and the cylinder head, between turbocharger and
front exhaust pipe etc. to make sure there are no leaks.
– Repair any leaks found.
1.6 Removing and installing bracket for

catalytic converter, Tiguan
♦ Rivet pliers, e.g. rivet pliers -VAS 6759-

Note
Depending on the equipment level of the vehicle, a retaining

washer for the bracket of the catalytic converter may be instal‐
led. When the vehicle »hits the ground«, the retaining washer
prevents the catalytic converter from slipping out of the bracket.
The retaining washer can also be retrofitted if necessary. For
retrofit parts, refer to ⇒ Electronic parts catalogue (ETKA).
To detach bracket from catalytic converter:
– Take electrical connector -2- out of bracket, unplug it and

move electrical wiring clear.
onto turbocharger.

insulation.
– If fitted, remove middle underbody cladding ⇒ General body

– Unscrew bolts -arrows-, and lower catalytic converter as far

as possible.
– Drill out pop rivets on rear of bracket and remove securing

clip.
– Detach bracket from catalytic converter.
To fit bracket with retaining washers:
– Check if pop rivets can be inserted into mounting on catalytic

converter. If necessary, widen holes to 7 mm with a drill.
– Fit bracket -1- to mountings on catalytic converter.
– Secure retaining washers -3- with rivets as shown in illustra‐
tion, parallel to rubber part -2-.

Further assembly is basically a reverse of the dismantling se‐

quence.
Specified torques ⇒ page 468

2 Emission control
⇒ o2.1 verview – emission control”, page 468
⇒ o2.2 verview - bracket and pipes for pressure differential
sender for particulate filterG1037”, page 473
⇒ a2.3 nd installing catalytic converter”, page 475
⇒ a2.4 nd installing holder of pressure differential sender for
particulate filterG1037”, page 484
⇒ a2.5 nd installing exhaust flap control unit”, page 485
2.1 Assembly overview – emission control

⇒ o2.1.1 verview - emission control, vehicles with front-wheel
drive”, page 468
⇒ o2.1.2 verview - emission control, vehicles with all-wheel
drive”, page 470
⇒ c2.1.3 onverter - specified torque and tightening sequence”,
page 472
2.1.1 Assembly overview - emission control,

vehicles with front-wheel drive
If particulate filter was renewed, learnt values must be adap‐
ted with ⇒ Vehicle diagnostic tester via Guided Engine Func-
tions Adapt particulate filter learnt values .

1 - Holder for pressure differ‐

ential sender for particulate fil‐
ter -G1037-
page 473
ling ⇒ page 484
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Union nut
❑ Apply high-temperature
paste to threads
❑ 45 Nm
5 - Union nut
paste to threads
❑ 45 Nm
❑ Consisting of:

-Z29-
❑ ⇒ page 433
7 - Nut
Specified torque and tighten‐
ing sequence ⇒ page 472
8 - Particulate filter
9 - Temperature sender after particulate filter -G527-
❑ Apply high-temperature paste to threads
❑ 45 Nm
10 - Clamping sleeve
❑ Align exhaust system free of tension before tightening ⇒ page 464 .
❑ Tighten threaded connections evenly.
11 - Union
12 - Union
13 - Bolt
❑ 20 Nm
14 - Bracket
15 - Temperature sender before particulate filter -G506-
2. Emission control 469

❑ 45 Nm
16 - Bolts
❑ 20 Nm
17 - Bracket
❑ For catalytic converter
18 - Catalytic converter
❑ With front exhaust pipe
❑ Protect catalytic converter from damage by knocks and impact
19 - Turbocharger
20 - Screw-type clamp
❑ Renew
❑ Specified torque and tightening sequence ⇒ page 472
21 - Seal
❑ Renew
Installation position of front clamping sleeve
– Fit clamp in position shown. Bolt -arrow- must not protrude

beyond lower edge of clamp.
2.1.2 Assembly overview - emission control,

vehicles with all-wheel drive

1 - Temperature sender after

particulate filter -G527-
paste to threads
❑ 45 Nm
2 - Nut
❑ 9 Nm
3 - Temperature sender be‐
fore particulate filter -G506-
paste to threads
❑ 45 Nm
❑ Consisting of:

-Z29-
❑ ⇒ o9.1 verview - Lamb‐
da probe”, page 433
❑ Consisting of:
Lambda probe -G39-
Lambda probe heater -

Z19-
❑ ⇒ o9.1 verview - Lamb‐
da probe”, page 433
6 - Bolts Volkswagen Technical Site: https://vwts.ru
❑ 20 Nm
7 - Pressure differential sender for particulate filter -G1037-
❑ Assembly overview ⇒ page 473
8 - Bolt
❑ 8 Nm
9 - Pressure pipes
❑ Assembly overview ⇒ page 473
10 - Heat shield
11 - Nut
❑ 8 Nm
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ 9 Nm

15 - Bolt
❑ 9 Nm
16 - Bracket
❑ For pressure line
17 - Union nut
❑ 45 Nm
18 - Union nut
❑ 45 Nm
Installation position of front clamping sleeve
– Fit clamp in position shown. Bolt -arrow- must not protrude

beyond lower edge of clamp.
2.1.3 Catalytic converter - specified torque

and tightening sequence
Installation position of screw-type clip for catalytic converter
– Fit screw-type clip in position shown. Make sure there is

sufficient clearance between bolted connection and other
components.
Catalytic converter - specified torque and tightening sequence

– Tighten bolted connections in stages in the sequence

shown:
Stage Screw-type clip/ Specified torque
nuts
1 -1, 3, 4- Screw in by hand as far as stop
• It should still be possible to move
catalytic converter and bracket.
2 -2- Tighten screw-type clip to 15 Nm.

3 -1, 3, 4- Tighten to 20 Nm
2.2 Assembly overview - bracket and pipes for pressure differential sender for
particulate filter -G1037-

1 - Heat shield
2 - Nut
❑ 8 Nm
3 - Elbow stud
4 - Pressure differential send‐
er for particulate filter -G1037-
❑ Securing bolt, 8 Nm
ling
5 - Retainer
6 - Bolt
❑ 9 Nm
7 - Heat shield
8 - Nut
❑ 8 Nm
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 20 Nm
13 - Pressure line
14 - Bolt
❑ 20 Nm
15 - Turbocharger

2.3 Removing and installing catalytic con‐

verter
⇒ a2.3.1 nd installing catalytic converter, vehicles with front-
wheel drive”, page 475
⇒ a2.3.2 nd installing catalytic converter, vehicles with all-wheel
drive”, page 479
2.3.1 Removing and installing catalytic con‐

verter, vehicles with front-wheel drive
Removing
Note
Fit all cable ties in the original position when installing.
– Remove connector for Lambda probe 1 after catalytic con‐

verter -GX7- from retainer, disconnect it, and lay electrical
wires to one side.
onto turbocharger.
– Remove lambda probe 1 after catalytic converter -GX7- ⇒

page 435 .
– Remove cross piece -1-.

– Unscrew temperature sensors -1- and -2- from particulate

filter ⇒ page 487 .
– Unscrew pipes for pressure differential sender from particu‐

late filter.

Vehicles with front differential lock
– Remove right wheel and front part of right wheel housing

liner/entire right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liner; Removing and
installing front wheel housing liner.
– Lower subframe ⇒ Running gear, axles, steering; Rep.
gr. 40; Subframe; Lowering subframe.
– Unscrew bolts -arrows- and remove heat shield -1-.
All vehicles
– Unscrew bolts -1- and -2-, and lay aside pipes.


Note
♦ Risk of damage to the flexible joint.

♦ Do not allow the flexible joint to bend by more than 10°.
Take care not to damage metal braiding on decoupling ele‐
ment.
– Loosen clamp -arrow-, and push it to rear. When doing this,

have a second mechanic hold the exhaust pipe.

Installing
– Insert screwdriver -2- into recess -arrow- on turbocharger,

and lever out seal -1-.
– Insert new seal.
– Fit screw-type clip in position shown to the turbocharger.
– Fit catalytic converter to turbocharger. Attach screw-type clip

of catalytic converter loosely without tightening it.

– Tighten nuts and screw-type clip. Make sure there is suffi‐

cient clearance between bolted connection and other com‐
ponents. Specified torque and tightening sequence ⇒ page
472 .
– Secure subframe ⇒ Running gear, axles, steering; Rep.
– Install temperature sensors ⇒ page 487 .
quence.
Specified torques
♦ ⇒ o2.1 verview – emission control”, page 468
cladding
2.3.2 Removing and installing catalytic con‐

verter, vehicles with all-wheel drive
Removing
Note
Fit all cable ties in the original position when installing.
– Remove connector for Lambda probe 1 after catalytic con‐

verter -GX7- from retainer, disconnect it, and lay electrical
wires to one side.
onto turbocharger.

– Remove lambda probe 1 after catalytic converter -GX7- ⇒

page 435 .
– Unscrew bolt -arrow- for pressure lines (next to tube fitting
for Lambda probe) from above.
– Unscrew nuts -arrows-, move clear bracket -1- for pressure

line, and move it aside.
– Lower subframe ⇒ Running gear, axles, steering; Rep.

– Unscrew bolts -arrows- and remove heat shield -1-.

– Unscrew temperature sender before particulate filter -G506-

-arrow- from particulate filter.
– Unscrew temperature sender after particulate filter -G527-

-arrow- from particulate filter.
– Unscrew union nut -arrow- for pressure lines, and move

aside pressure lines.

Note
♦ Risk of damage to the flexible joint.

♦ Do not allow the flexible joint to bend by more than 10°.
Take care not to damage metal braiding on decoupling ele‐
ment.
– Loosen clamp -arrow-, and push it to rear. When doing this,

have a second mechanic hold the exhaust pipe.

Installing
– Insert screwdriver -2- into recess -arrow- on turbocharger,

and lever out seal -1-.
– Insert new seal.
– Fit screw-type clip in position shown to the turbocharger.
– Fit catalytic converter to turbocharger. Attach screw-type clip

of catalytic converter loosely without tightening it.
– Tighten nuts and screw-type clip. Make sure there is suffi‐
cient clearance between bolted connection and other com‐
ponents. Specified torque and tightening sequence ⇒ page
472 .
– Secure subframe ⇒ Running gear, axles, steering; Rep.
– Install temperature sensors ⇒ page 487 .
quence.
Specified torques
♦ ⇒ o2.1.2 verview - emission control, vehicles with all-wheel
drive”, page 470
cladding


2.4 Removing and installing holder of pres‐

sure differential sender for particulate
filter -G1037-
– Pull off connector -1- of pressure differential sender for par‐
ticulate filter -G1037-.
– Remove catalytic converter ⇒ page 475 .

– Unscrew bolts -arrows- and nut -1-. Detach cover section.
– Unscrew bolts -arrows-, and detach bracket with hoses.
Installing
The assembly steps are basically a reverse of the dismantling
procedure.
Specified torques
♦ ⇒ o2.1 verview – emission control”, page 468

2.5 Removing and installing exhaust flap

control unit
Removing
– Unscrew nuts -4-, and remove exhaust flap control unit -2-.
Installing

– Bring exhaust flap control unit into installation position.
• Key -2- must engage in grooves -arrows- of exhaust flap -1-.
Specified torques
♦ ⇒ Fig. ““Exhaust flap control unit – specified torque”“, page
441

3 Exhaust gas temperature regulation

⇒ o3.1 verview – exhaust gas temperature regulation”, page
486
⇒ a3.2 nd installing parts of exhaust gas temperature regula‐
tion”, page 487
3.1 Assembly overview – exhaust gas tem‐

perature regulation
Assembly overview - exhaust gas temperature regulation, front-
wheel drive

sender 3 -G495-
❑ Comprised in dual ex‐
sender 1 -GX41-
❑ 45 Nm
sender 4 -G648-
sender 1 -GX41-
❑ 45 Nm
Assembly overview - exhaust gas temperature regulation, all-

wheel drive


sender 3 -G495-
sender 1 -GX41-
❑ 45 Nm
sender 4 -G648-
sender 1 -GX41-
❑ 45 Nm
3.2 Removing and installing parts of ex‐

haust gas temperature regulation
⇒ a3.2.1 nd installing exhaust gas temperature sender, vehicles
with front-wheel drive”, page 487
⇒ a3.2.2 nd installing exhaust gas temperature sender, vehicles
with all-wheel drive”, page 489
3.2.1 Removing and installing exhaust gas

temperature sender, vehicles with
front-wheel drive
♦ Tool set -T10395A- with suitable insert
Removing
• Observe safety precautions when working on the exhaust
system ⇒ page 3 .
– Loosen centre left underbody cladding working towards ex‐
haust system, and push it downwards slightly ⇒ General
body repairs, exterior; Rep. gr. 66; Underbody cladding; As‐
sembly overview - underbody cladding.
3. Exhaust gas temperature regulation 487


and free off electrical wires.
– Unscrew exhaust gas temperature sender 3 -G495- -arrow-.
Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
– Bring exhaust gas temperature sender 4 -G648- into installa‐
tion position:

• Angle -α- = max. 15°.

Specified torques
♦ ⇒ page 486
cladding; Assembly overview - underbody cladding
3.2.2 Removing and installing exhaust gas

temperature sender, vehicles with all-
wheel drive
♦ Tool set -T10395A- with suitable insert
Removing
• Observe safety precautions when working on the exhaust
system ⇒ page 3 .
– Loosen centre left underbody cladding working towards ex‐
haust system, and push it downwards slightly ⇒ General
body repairs, exterior; Rep. gr. 66; Underbody cladding; As‐
sembly overview - underbody cladding.
and free off electrical wires.

Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
tion position:

• Angle -α- = max. 15°.

tion position:
• Angle -α- = max. 15°.

Specified torques
♦ ⇒ page 486
cladding; Assembly overview - underbody cladding

28 – Ignition system
1 Ignition system
⇒ o1.1 verview - ignition system”, page 492
⇒ a1.2 nd installing ignition coils”, page 494
⇒ a1.3 nd installing knock sensor 1G61”, page 496
⇒ a1.4 nd installing Hall sender”, page 497
⇒ a1.5 nd installing engine speed senderG28”, page 499
1.1 Assembly overview - ignition system
492 Rep. gr.28 - Ignition system

1 - Bolt
❑ The specified torque in‐
fluences the function of
the knock sensor.
❑ 8 Nm +90°
2 - Knock sensor 1 -G61-
knock sensor 1G61”,
page 496
3 - Spark plug
❑ 30 Nm
4 - Spark plug connector
❑ Fitting position ⇒
a1.2 nd installing igni‐
tion coils”, page 494
5 - Ignition coil
♦ Ignition coil 1 -N70-
ignition coils”, page 494
6 - Bolt
❑ 10 Nm
7 - Nut
❑ 9 Nm
8 - Bolt
❑ 9 Nm
❑ Removing and installing ⇒ a1.4.2 nd installing Hall sender 2G163”, page 498
10 - O-ring
11 - O-ring
12 - Hall sender -G40-
❑ Removing and installing ⇒ a1.4.1 nd installing Hall senderG40”, page 497
13 - Bolt
❑ 9 Nm
14 - O-ring
15 - Engine speed sender -G28-
❑ Removing and installing ⇒ a1.5 nd installing engine speed senderG28”, page 499
16 - Bolt
1. Ignition system 493

❑ 4 Nm +45°
1.2 Removing and installing ignition coils

The ignition coils are easier to remove when the engine is
warm. The grease used when assembling at the factory makes
it easier to remove the ignition coils and spark plug connectors
when the engine is warm.
♦ Puller -T10530-
♦ Silicone paste ⇒ Electronic parts catalogue.

Removing
er”, page 76 .
– Remove electrical connector -2- for Lambda probe 1 before
catalytic converter -GX10- from bracket, and disconnect it.
– Unscrew nut -2- and free off earth wire -1-.

– Release electrical connectors while simultaneously pulling

them off ignition coils -arrows-.
– Insert puller -T10530- into hole -1- in ignition coil.
– Turn knurled nut -2- clockwise -arrow- until puller is secure.

– Using puller -T10530-, carefully pull out ignition coil in verti‐
cal direction -arrow-.

Installing
Installation is carried out in the reverse order. When installing,

note the following:
– Apply thin bead of silicone paste on circumference of sealing
hose of ignition coil with output stage -arrow-.
NOTICE
Risk of irreparable damage to ignition coil if unsuitable lubri‐
cant is used.
– Only use prescribed silicone paste.
– Press ignition coils onto spark plugs by hand evenly (do not
use tools).
page 76 .
Specified torques
♦ ⇒ o1.1 verview - ignition system”, page 492
1.3 Removing and installing knock sensor

1 -G61-
Location: beneath intake manifold behind actuator for engine
temperature regulation -N493-.
Removing
– Remove actuator for engine temperature regulation -N493-
⇒ a2.8 nd installing actuator for engine temperature regula‐
tionN493”, page 301 .

– Free off electrical wire -1- for knock sensor 1 -G61-. To do

this, release fastener -arrow- and pull off from retainer -2-.
– Unscrew bolt -arrow- and take out knock sensor 1 -G61-.
Installing
• Note installation position.
– Install actuator for engine temperature regulation -N493- ⇒
a2.8 nd installing actuator for engine temperature regula‐
tionN493”, page 301 .
Specified torques
1.4 Removing and installing Hall sender

⇒ a1.4.1 nd installing Hall senderG40”, page 497
⇒ a1.4.2 nd installing Hall sender 2G163”, page 498
1.4.1 Removing and installing Hall sender -

G40-

♦ Bit -T10573-
Removing
er”, page 76 .
– Unscrew bolt -1-, remove Hall sender -G40- -item 2-.

Installing
• Check O-ring for damage.
page 76 .
Specified torques
1.4.2 Removing and installing Hall sender 2

-G163-
Removing
er”, page 76 .

– Unscrew bolt -2- and remove Hall sender 2 -G163-.

Installing
page 76 .
Specified torques
1.5 Removing and installing engine speed

sender -G28-
Removing
371 .
– Unscrew bolt -arrow- and take out engine speed sender

-G28-.
Installing
Specified torques

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

2.6 Removing and installing air intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

1.1 Safety regulations for working on fuel supply

Danger of fire caused by escaping fuel

1.2 Safety measures when working on vehicles with start/stop system

1.4 Safety precautions when working on ignition system

Risk of damage to components

1.5 Safety precautions when working on the cooling system

2 Rep. gr.00 - Technical data

1.6 Safety precautions when working on exhaust system

Risk of damage to flexible joint

2.1 Engine number/engine data

The engine code is also stamped on the cylinder block behind

4 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

Codes DNFG DSFB DSFE DSFF DNFC DNFE

Codes DNPA DRNA DNNA DNND

Volkswagen Technical Site: https://vwts.ru

3.1 Rules for cleanliness

3.2 Initial diagnoses

6 Rep. gr.00 - Technical data

– Connect vehicle diagnostic tester.

3.3 Foreign objects in engine

3.4 Contact corrosion

3.5 Routing and attachment of lines

3.6 Fitting radiator and condensers

3.7 Checking vacuum system

♦ Hand operated vacuum pump -VAS 6213-

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

♦ Engine support -T10359 A-

1. Removing and installing engine 9

♦ Release lever -80 - 200-

The engine is removed downwards with gearbox. To do this, the

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

10 Rep. gr.10 - Removing and installing engine

– Place drip tray for workshop hoist -VAS 6208- underneath.

– Battery in engine compartment: Remove battery tray -1-

– Press release tabs on vacuum hose -1-, and remove hose

1. Removing and installing engine 11

Vehicles without auxiliary heater:

– Lift retaining clips -arrows- and disconnect coolant hoses

– Detach electrical connectors -1, 2- from bracket, unplug con‐

12 Rep. gr.10 - Removing and installing engine

1. Removing and installing engine 13

– Release hose clips -1, 2-, and remove coolant hoses.

– Lift retaining clip -arrow- and disconnect coolant hose (top

14 Rep. gr.10 - Removing and installing engine

Golf, Passat, Arteon:

– Separate connector -1- on engine control unit -J623- ⇒ page

– Release catch using a screwdriver -arrow- and detach cover

1. Removing and installing engine 15

– Remove nut -arrow-, detach electrical wiring and move clear.

– Release and pull off connector on engine control unit -J623-